Abrasive Particle with at Most Three Surfaces and One Corner

ABSTRACT

An abrasive particle includes at most three surfaces and at least one edge which has a corner at at least one end. The abrasive particle may contain a ceramic material, particularly polycrystalline α-Al 2 O 3 . Abrasive particles as a whole, methods for producing abrasive particles, moulds, abrasive articles, methods for producing abrasive articles, and methods for abrading a surface are also disclosed.

This application is a divisional application of copending U.S. patentapplication Ser. No. 14/417,848 filed on Jan. 28, 2015, which is a 35U.S.C. § 371 National Stage Application of PCT/EP2013/066095, filed onJul. 31, 2013, which claims the benefit of priority to (i) patentapplication no. DE 10 2012 213 633.9, filed on Aug. 2, 2012 in Germany,(ii) patent application no. DE 10 2012 213 627.4, filed on Aug. 2, 2012in Germany, (iii) patent application no. DE 10 2012 213 630.4, filed onAug. 2, 2012 in Germany, and (iv) patent application no. EP 12178932.5filed on Aug. 2, 2012 in Europe. The disclosures of the above-identifiedpatent applications are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

The present invention relates to abrasive grains having a defined shape,to collectives of abrasive grains, to processes for producing abrasivegrains, to dies, to abrasive articles comprising abrasive grains, toprocesses for producing abrasive articles and to processes for grindinga surface with an abrasive article.

BACKGROUND

Abrasive grains, especially ceramic abrasive grains, having a definedshape and size have been known for some time.

U.S. Pat. No. 5,201,916 discloses, inter alia, flat abrasive grainshaving, for example, a triangular, rectangular or circular shape. Theseabrasive grains are produced from a dispersion comprising particlesconvertible to α-alumina and a liquid comprising a volatile component.The dispersion is poured into a die having a flat base surface anddepressions having shapes complementary to the desired shapes of theabrasive grains. Subsequently, a portion of the volatile component isremoved, so as to form a precursor having the desired shape. Theprecursor is then removed from the die, calcined and finally sintered,so as to form the finished abrasive grain.

The abrasive grains produced by this process have two opposite basefaces having essentially the same geometric shape. A longer lifetime isascribed to the abrasive grains since small pieces are constantlybreaking off from the abrasive grains during the grinding, giving riseto new cutting faces. As a result, the abrasive grains sharpenthemselves. It is believed that about one to two thirds of abrasivegrains having a base face in the shape of a triangle, especially of anequilateral triangle, on electrostatic scattering, are oriented suchthat one tip points away from the underlayer, while other abrasivegrains are oriented such that the tip points toward the underlayer.

In an alternative process described in EP 615 816, elongated bar-shapedprecursors are first produced by means of extrusion, and these are thendivided into individual abrasive grains. The bar-shaped abrasive grainsmay thus have, for example, a cylindrical or prism shape.

WO 2009/085841 describes a further production process in which theprecursor is dried in the die under conditions which lead to fracturingof the precursor. The fragments have, at least to some degree, surfacesand edges which are complementary to the corresponding surfaces andedges of the die and therefore have the angles defined by the die. Thesesurfaces and edges have elevated cutting capacity. The other surfacesand edges formed by the fracturing, in contrast, are irregular.

WO 2010/077495 discloses abrasive grains having a through-opening or anon-through-opening or having a dish shape. Also described therein areproduction processes for such abrasive grains. Further abrasive grainshaving undefined openings are disclosed in WO 2010/077518. WO2010/077491 is likewise concerned with abrasive grains having a dishshape.

WO 2010/077519 discloses abrasive grains having two opposite main facesand lateral faces that are inclined with respect to the main faces andrun between them. The different lateral faces of an abrasive grain maybe inclined at different angles relative to the main faces.

The document WO 2011/068724 likewise discloses abrasive grains having abase side and a tip, and also inclined lateral faces that run betweenthem. Similar abrasive grain forms are also described in WO 2011/109188.

The document WO 2010/077509 is concerned with abrasive grains having asurface having a multitude of grooves. These grooves are produced withthe aid of complementary ridges on the underside of the die.

WO 2011/068714 discloses pyramidal abrasive grains having aparallelogram-shaped, especially rhombic, base face, a kite-shaped baseface and a superelliptical base face.

WO 2011/139562 discloses abrasive grains in the form of tetrahedra andmodifications thereof. For example, the lateral faces may be concave orconvex, the corners of the tetrahedra may be truncated, or the edges maybe curved.

The abrasive grains described in WO 2012/018903 contain two or moresections in the form of plates arranged at an angle to one another.

In the process described in WO 2012/061016, an abrasive structure isfirst produced, containing abrasive grain precursors joined to oneanother via frangible connecting elements. After the sintering, theabrasive grains are separated from one another by breaking theconnecting elements.

Alternatively, abrasive grains of a defined shape can also be producedby a screen printing process. This is described, for example, by WO96/12776. This involves passing a dimensionally stable dispersionthrough orifices having a defined shape onto a conveyor belt and thencuring said dispersion. The orifices may be present, for example, in amovable continuous belt.

A development of the screen printing process is disclosed in WO2011/087649. In this process, the dispersion is forced through theorifices in the continuous belt by means of a pressure differential.Given suitable choice of the viscosity of the dispersion, this processcan produce abrasive grains having a cross section which narrows from afirst main side to a second, opposite the main side.

WO 2012/061033 describes processes for producing abrasive grains of adefined shape with the aid of laser radiation. Additionally disclosedare specific shapes of abrasive grains. For example, the abrasive grainsmay contain a main element and at least three bar-shaped elements thatextend therefrom. More particularly, the abrasive grain may have theshape of a cross, of an uppercase letter “T”, of a star or of a Greeklowercase letter “λ”.

In general, it is assumed that abrasive grains having a defined shapehave improved properties in several aspects: if the abrasive grainsalready have a defined shape and size on commencement of productionthereof, there is no need for a subsequent sorting step by which theabrasive grains subsequently have to be divided into different sizefractions. In addition, the shapes and sizes also remain unchangedbetween different production batches, which means that the abrasiveproperties have very good reproducibility. Furthermore, the abrasivegrains may, for example, achieve increased total material removal, havea longer lifetime, produce an increased surface quality of the processedsurface and give an abrasion outcome of better reproducibility.

Nevertheless, the abrasive grains known from the prior art have a numberof disadvantages. For example, a large number of abrasive grains have tobe aligned with the aid of costly and inconvenient electrostaticscattering and applied to an underlayer, in order that, for example,corners and/or edges of the abrasive grain point away from theunderlayer and hence toward a surface to be processed. Without such analignment, the material removal and/or the service life of an abrasivearticle would only be very low.

SUMMARY

It is therefore an object of the present invention to at least partlyremedy the disadvantages of the prior art. More particularly, theintention is thus to provide an abrasive grain which, especially withthe aid of mechanical scattering, can be applied to an underlayer in adesired orientation with maximum probability. For example, at least onecorner of the abrasive grain should point away from the underlayer in adesired orientation.

The object is also achieved by an abrasive grain having a defined shape,the abrasive grain having not more than three surfaces and containing atleast one edge. At at least one end of the edge, the abrasive grain hasa corner.

An abrasive grain having such a shape assures that the abrasive grain,especially on mechanical scattering, will always be aligned on anunderlayer in such a way that a corner and/or an edge protrudes from theunderlayer. More particularly, no costly and inconvenient methods foralignment of the abrasive grains are needed (for example electrostaticscattering) in order to achieve optimal abrasion results. The abrasivegrain or a multitude of abrasive grains can be applied as a bulkmaterial.

Here and hereinafter, a face is understood to mean a continuoustwo-dimensional part of the surface of the abrasive grain, whichconsists of points with which a well-defined theoretical tangentialplane can be placed on the abrasive grain in each case. Such a face maybe flat or curved; it may also have at least one flat section and atleast one curved section which merge into one another without anintermediate edge.

An edge is a coherent one-dimensional portion of the surface of theabrasive grain, which consists of points at which two areas or twoportions of one and the same area are in contact with one another, witha non-continuous profile of the tangential planes of the two areas orarea portions at these points. At the edge, there is preferably aninternal angle of less than 150°, preferably less than 120°, morepreferably less than 90°, or greater than 210°, preferably greater than240°, more preferably greater than 270°. The internal angle is the anglebetween the two tangential planes of the two areas or area portionsmentioned, i.e. the angle between the normal vectors to these tangentialplanes.

A point on the surface of the abrasive grain is understood to be acorner when an imaginary cone can theoretically be placed over a portionof the abrasive grain such that this portion of the abrasive grain iswithin the cone and the point forms the tip of the cone. Preferably, theopening angle of the cone is less than 150°, further preferably lessthan 120° and more preferably less than 90°.

The abrasive grain may have at least four corners, especially exactlyfour corners. Through a suitable spatial distribution of the fourcorners, it is possible to ensure that at least one corner stands apartfrom an abrasive underlayer on which the abrasive grain lies. For thispurpose, for example, the four corners should not be in a common plane.It is thus always assured that an optimal grinding outcome can beachieved.

The abrasive grain may have at least two edges which are not in contactwith one another and which are each bounded by two corners. A firststraight connecting line between the corners that bound a first edge maybe skewed with respect to a second straight connecting line between thecorners that bound a second edge. The straight connecting lines aremerely theoretical lines which need not in fact correspond to actualedges of the abrasive grain. The angle between these straight connectinglines formed may be 90°±50°, preferably 90°±30°, more preferably90°±10°. The angle between skewed straight lines is measured by drawingthe two skewed straight lines in such a way that the commonperpendicular, i.e. the straight line which is at right angles to thetwo skewed straight lines, is represented as a point. It will beappreciated that the common perpendicular must intersect the straightlines between the corners that bound the edge. By virtue of the abrasivegrain having two edges each bounded by two corners, with straightconnecting lines skewed relative to one another, it is possible toassure that one corner of the abrasive grain will always stand apartfrom an underlayer. Such an orientation of the abrasive grains canespecially also be achieved by a mechanical scattering operation.

In the case of an abrasive grain having at least four corners, there maybe an angle between two planes formed by three corners each of between70° and 140°, preferably between 80° and 130°, more preferably between90° and 120°. According to the configuration of the angle between theseplanes, the abrasion characteristics of the abrasive grain may beinfluenced. If the abrasive grain always has the same alignment, theprotruding corner of the abrasive grain, for example, is at an acuteangle, a right angle or an oblique angle from an underlayer. The anglebetween the planes is understood to mean the angle between the normalvectors of the two planes. It will be appreciated that the planes eachformed from three corners of the abrasive grain may not be identical tothe faces of the abrasive grain.

The abrasive grain may have at least one feature of symmetry. Forexample, it may have at least one plane of symmetry, in which case theabrasive grain is transformed into itself by a theoretical reflection atthis plane of symmetry. The plane of symmetry may, for example, run atright angles to a straight line which is formed by two corners of theabrasive grain. Alternatively or additionally, the abrasive grain mayhave at least one axis of symmetry, in which case the abrasive grain istransformed into itself by a rotation by 180° about an axis of symmetry.On the basis of such features of symmetry, the abrasive grain maybearranged in two or more different orientations on the underlayer,although they cause the same abrasive effect. In addition, a feature ofsymmetry, especially in the presence of a plane of symmetry, canfacilitate the production of an abrasive grain since it is thus possibleto use, for example, two similar or even identical dies.

In some working examples in which the abrasive grain has exactly twofaces, these faces may both be curved. In other working examples inwhich the abrasive grain has exactly three faces, at least two or allthree of these faces may be curved. For example, the faces may beconcave or convex. It is likewise conceivable that an abrasive grain hasonly one single 2 0 closed face. For example, an abrasive grain havingonly two edges and one face may be configured like a tetrahedron, inwhich case, however, there are effectively only two opposite or skewededges of the tetrahedron as edges of the abrasive grain. The remainingfour edges of the tetrahedra may, for example, be rounded off so as toform a circumferential, continuously curved, closed surface.

The edges of the abrasive grain may take the form of a curved line, inwhich case the curvature may be concave or convex.

The shape and size of the abrasive grain can be determined, forinstance, with the aid of a microscope. The inventive abrasive grain mayhave a size over the entire size range which is also customary forconventional abrasive grains. Typically, abrasive grains having greatersizes lead to higher material removal from a processed surface thansmall abrasive grains. For example, the abrasive grain may have a sizein the range from 100 μm to 2000 μm. This size can be determinedexperimentally with the aid of a microscope. It is understood to meanthe diameter of a circle enveloping the microscope image of the abrasivegrain, i.e. the smallest diameter of a circle that encloses the image.

The above-described shape of the abrasive grain is an idealized shape.However, the invention also encompasses abrasive grains which differfrom this idealized shape within the scope of manufacturing tolerances.Possible deviations from the idealized shape may have one or more of thefollowing causes:

-   -   cavities or bubbles caused by enclosed air and/or other gases in        a dispersion from which the abrasive grains are produced;    -   absent corners and/or edges which arise through incomplete        filling of a die and/or during the removal of a precursor of the        abrasive grain from a die;    -   collapsed side faces and/or edges which arise through shrinkage        during the removal of a portion of the volatile components of        the dispersion; especially collapsed faces which arise from the        upper free surface of the dispersion which is not in contact        with the die;    -   material that has flaked away, caused by a drying and/or        sintering process;    -   broken corners and/or edges which arise through transport and/or        during further processing of the abrasive grains as bulk        material.

The deviations from the ideal case need not necessarily lead todisadvantageous properties of the abrasive grain. For example, brokencorners and/or edges may also have the effect that further cutting edgesarise compared to the ideal case, which can even have a positive effecton the abrasive action.

More particularly, the invention also encompasses abrasive grains whoseshape corresponds only essentially to the idealized shape. For example,a portion of the surface of the abrasive grain is also regarded as a(single) face when this proportion actually contains two or more areaportions, each of them coherent, which are in contact with one anotherat an edge at which an internal angle within the range from 160° to200°, preferably from 170° to 190°, more preferably from 175° to 185°,is formed. In addition, a point on the surface is regarded as a cornerwhen there is actually curvature at that point, but with radii ofcurvature of not more than 10%, preferably not more than 5%, morepreferably not more than 2%, of the above-defined size of the abrasivegrain.

Preferably, however, the abrasive grain has an idealized shape asdescribed above.

The abrasive grain may, for example, comprise or consist of a ceramicmaterial, especially a polycrystalline ceramic material. Preferably, theabrasive grain comprises alumina, more preferably α-Al₂O₃.

Alternatively or additionally, the abrasive grain may also comprise atleast one further metal oxide, for instance sodium oxide, magnesiumoxide, iron oxide, silicon oxide, calcium oxide, zirconium oxide,yttrium oxide, zinc oxide, cobalt oxide, nickel oxide, hafnium oxide,chromium oxide, praseodymium oxide, samarium oxide, ytterbium oxide,neodymium oxide, lanthanum oxide, gadolinium oxide, cerium oxide,dysprosium oxide, erbium oxide, lutetium oxide, titanium oxide,manganese oxide or any desired combinations thereof.

Many of these metal oxides originate from impurities in the startingmaterials, for example in alumina. Given sufficiently low proportions inthe abrasive grain, however, such impurities have no adverse effect onthe production and use of the abrasive grain. Some of these impuritiesmay even have a positive effect on the abrasive grain.

Fractions of zirconium oxide or yttrium oxide may originate, forexample, from grinding balls which can be used in a grinding step in theproduction of the abrasive grains. Fractions of iron oxide may originatefrom a grinding vessel which is used in such a grinding step.

Likewise alternatively or additionally, the abrasive grain may comprisefurther hard substances, for example silicon carbide.

In addition, the abrasive grain may comprise at least one breakdownproduct of a dispersant described in detail hereinafter, which was usedin the production of the abrasive grains. In addition, the abrasivegrain may comprise at least one nucleating agent or breakdown productthereof which was used in the production of the abrasive grains. Thenucleating agent may, for example, be magnesium oxide which has alreadybeen mentioned above.

Moreover, the abrasive grain may also comprise at least one of thefurther substances described in EP 615 816 A1.

The ingredients mentioned can be determined with the aid of chemicalanalysis methods known per se.

The abrasive grain may comprise or consist of a structure having one ormore different phases. A first phase may consist of alumina, morepreferably of α-Al₂O₃. A second phase may consist of one or more of theabovementioned further metal oxides and/or further hard substances.

The proportion of alumina, especially of α-Al₂O₃, in the abrasive grainmay, for example, be at least 25% by weight, preferably at least 50% byweight, further preferably at least 70% by weight, more preferably atleast 95% by weight.

The abrasive grain may have a coating which covers only part of thesurface, especially only one or more edges and/or only one of severalflat areas of the surface. The coating may, for instance, be aferromagnetic or paramagnetic coating. Such a partial coating of thesurface with a ferromagnetic or paramagnetic material enables alignmentof the abrasive grain in a given direction in a magnetic field appliedduring the scattering operation. Alternatively, it may also be a coatingof a material having elevated thermal conductivity or a coating whichenables increased adhesion of the abrasive grain on the abrasiveunderlayer.

A further aspect of the invention relates to a collective of abrasivegrains. A collective of abrasive grains is understood here andhereinafter to mean a coherent collection of abrasive grains. Forexample, this may be a collection of abrasive grains which are presentin a container and are stored and/or transported as such, for example ina sack.

Such a collection of abrasive grains can also be used to produce anabrasive article. A collective of abrasive grains is also regarded asthe entirety of all the abrasive grains present in an abrasive article.

Preferably, the collective of abrasive grains contains at least 20% byweight, preferably at least 50% by weight and more preferably at least90% by weight of inventive abrasive grains as described above. The otherabrasive grains present in the collective may likewise have a definedshape, but one which differs from the inventive shape, or they may nothave a defined form since they are, for example, broken abrasive grains.These other abrasive grains present in the collective are also referredto as “support grains”.

It is conceivable and likewise within the scope of the invention thatthe inventive abrasive grains present in the collective are differentfrom one another. For example, the collective of abrasive grains maycontain a first fraction of abrasive grains of a first embodiment of theinvention, and a second fraction of abrasive grains of a secondembodiment of the invention that are different from the first embodimentof the invention. More particularly, the abrasive grains of the firstembodiment of the invention may differ in terms of size and/or shapefrom the abrasive grains of the second embodiment of the invention.

The collective of abrasive grains may consist exclusively of identicalinventive abrasive grains; more particularly, the collective in thatcase has a size distribution in the form of points.

The collective of abrasive grains may essentially have a sizedistribution which corresponds to a size standard customary in theabrasives industry, for example the American National StandardsInstitute (ANSI), the Standards of the Federation of European Producersof Abrasives (FEPA) or the Japanese Industrial Standard (JIS). Forexample, the collective of abrasive grains may essentially have a grainsize of P12, P16, P20, P24, P30, P36, P40, P50, P60, P80, P100, P120,P150, P180, P220, P240, P280, P320, P360, P400, P500, P600, P800, P1000,P1200, P1500, P2000, P2500, P3000 or P5000 according to the FEPAstandard. In this context, a size distribution “essentially” means thatat least 90% by weight, preferably at least 95% by weight, furtherpreferably at least 99% by weight and more preferably all of theabrasive grains in the collective of abrasive grains meet this standard.

As already described above, it is also conceivable that the collectivecontains at least two different fractions of inventive abrasive grainsand/or at least one fraction of noninventive abrasive grains. Each ofthese fractions may itself have a size distribution corresponding ineach case to one of the abovementioned size standards customary in theabrasives industry.

An inventive abrasive grain or an inventive collective of abrasivegrains can be produced, for example, by the following process known fromU.S. Pat. No. 5,201,916:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. introducing the dispersion into at least one depression of a        die;    -   c. optionally squeegeeing an upper face of the die in order to        remove at least a portion of the dispersion which stands above        the upper face of the die;    -   d. removing a portion of the volatile components of the        dispersion, so as to form at least one abrasive grain precursor;    -   e. removing the abrasive grain precursor from the die;    -   f. optionally calcining the abrasive grain precursor;    -   g. sintering the abrasive grain precursor in order to obtain at        least one abrasive grain.

Before and/or during the production of the dispersion in step a), theraw materials, especially α-alumina particles and/or particles that canbe converted to α-alumina, are ground. This can be effected, forexample, with the aid of a ball mill, especially with the aid of aplanetary ball mill or an attritor.

The dispersion may comprise at least one dispersant. Such a dispersantfacilitates the formation of the dispersion and increases the stabilitythereof by, for example, forming layers around the individual grainswhich prevent lump formation. The dispersant may, for example, be apolymer. In general, the dispersant breaks down during the sintering instep g) if not earlier.

For production of the inventive abrasive grains, it is possible to use acasting mold, said casting mold comprising at least one die having atleast one depression having a particular surface, the surface beingcomplementary to the shape of at least a portion of the surface of theabrasive grain.

The die may comprise or consist of silicone, for example. Thedepressions may have an open top face through which the dispersion canbe introduced. The depressions in the die each have a surface whoseshape is complementary to the shape of at least one portion of thesurface of the desired abrasive grain.

The precursor formed in step d) should preferably have sufficientmechanical stability to be further processible as bulk material in thesubsequent steps. The optional calcining in step f) is advantageous oreven required especially when the dispersion comprises a plurality ofdifferent raw materials and a phase transformation is required.

In a development of the process known from U.S. Pat. No. 5,201,916, theabovementioned die is advantageously just one part of a multipartcasting mold which additionally comprises at least one shaping element,especially a further die or a ram element with which, in addition to thesurface shaped in the first die, at least a portion of the remainingsurface of the abrasive grain can be shaped.

Preferably, the ram elements do not completely close off the depressionsof the die, such that the volatile component of the dispersion canescape.

More complicated shapes of abrasive grain bodies can be shaped in diesthat can be assembled, in a similar manner to injection moldingprocesses. For this purpose, at least one die has at least oneintroduction opening through which the dispersion can get into thedepressions.

Another aspect of the invention relates to an abrasive articlecontaining a collective of abrasive grains as described above. Moreparticularly, it is thus possible for at least 20% by weight, preferablyat least 50% by weight, more preferably at least 90% by weight, of allthe abrasive grains of the abrasive article to take the form ofinventive abrasive grains as described above. The other abrasive grainsmay likewise have a defined shape, but one which differs from theinventive shape, or they may not have a defined shape.

The abrasive article may, for example, be a coated abrasive article, anabrasive article web, a bonded abrasive article or an abrasive brush.

A coated abrasive article comprises an underlayer, especially a flexibleunderlayer, for example paper, vulcanized fiber, a film, a textilematerial, a foam or multilayer combinations thereof. The abrasive grainscan be secured to the underlayer with the aid of a base binder (“makecoat”). The make coat and the abrasive grains may be covered with a topbinder (“size coat”). Optionally, above the size coat mentioned, it isalso possible for a second top binder (“supersize coat”) to be present.

The make coat, size coat and supersize coat used may be any bindersknown per se, for example composed of synthetic resin, for instance aphenolic resin, an epoxide, a urea resin, a melamine resin or anunsaturated polyester resin. The size coat and/or supersize coat mayadditionally comprise further customary active ingredients and/orfillers.

The abrasive article may be in different product forms, for example asan abrasive disk or as an abrasive belt.

The invention also encompasses a process for producing an inventiveabrasive article as described above. The process comprises a step inwhich a collective of abrasive grains is fixed on and/or in a substrate,especially by means of a binder. The substrate may, for instance, be anunderlayer, especially a flexible underlayer, of a coated abrasivearticle, a web material for an abrasive web, a matrix for a bondedabrasive or bristle for an abrasive brush. In the case of a coatedabrasive article, the make coat and/or the abrasive grains and/or thesize coat and/or supersize coat can be applied by a method known per se.For example, the abrasive grains can be applied by electrostatic ormechanical means (i.e. by gravimetric means). Because of the inventiveshape of the abrasive grains, even in the case of mechanical scattering,a high proportion of the abrasive grains will be oriented on an abrasiveunderlayer such that at least one corner of the abrasive grain pointsaway from the underlayer. It is thus possible to dispense with morecomplex electrostatic scattering.

In addition, the invention is also directed to a process for grinding asurface with an abrasive article as described above. The surface mayespecially be a painted surface. In the case of a painted surface,abrasive grains having sizes of 500 μm or less are particularlysuitable.

The object is also achieved by an abrasive grain with a defined shapewhich comprises or consists of at least one component having essentiallythe shape of a twisted geometric elementary body. Preferably, thecomponents are theoretical components from which the overall abrasivegrain is composed only in a theoretical sense. The fact that theabrasive grain comprises or consists of at least two or more componentsshould thus not necessarily be understood to the effect that theabrasive grain has been or is joined together from two or morecomponents produced separately at first. Instead, the inventive abrasivegrains are preferably formed and produced in one piece. The term“component” is also used here in the sense that an abrasive grain mayconsist only of a single component.

A body in the form of a twisted geometric elementary body is understoodhere and hereinafter to be a component having the following properties:the component contains a theoretical twist axis which cuts through thecomponent and runs through a reference point on the surface of thecomponent. The cross sections of the component that run at right anglesto the twist axis are rotated about the twist axis relative to theelementary body by an angle, this angle depending on the distance of thecross section from the reference point. There is thus at least one firstsectional plane at right angles to the twist axis in which the crosssection of the component is rotated by a first angle relative to theelementary body, and a second sectional plane at right angles to thetwist axis in which the cross section of the component is rotated by asecond angle relative to the elementary body, the second angle beingdifferent from the first. The two angles mentioned may differ from oneanother by an angle differential in the range from 15° to 180°,preferably in the range from 20° to 180°, further preferably in therange from 30° to 150°, even further preferably in the range from 45° to135°, more preferably in the range from 60° to 120° and most preferably90°.

The above-described angle differentials may especially exist between twosectional planes in opposite surface regions of the component,especially between two opposite surfaces of the abrasive grain. Theangle differential between two opposite surfaces is referred to here andhereinafter as overall twist angle. If the abrasive grain takes the formof a twisted cuboid having rectangular, especially square, base and topfaces, the overall twist angle between the base and top face isadvantageously in the range from 60° to 120°, preferably from 70° to110° and further preferably from 80° to 100°, and is more preferably90°. If, in contrast, the abrasive grain takes the form of a twistedprism having base and top faces in the form of equilateral triangles,the overall twist angle between the base and top face is advantageouslyin the range from 5° to 30°, preferably from 5° to 20°, more preferablyfrom 5° to 15°. In some other working examples, however, angledifferentials, especially overall twist angles, of about 45° areadvantageous, as will be explained hereinafter.

In some embodiments, the angle mentioned has a linear dependence on thedistance of the sectional plane from the reference point.

In many embodiments, the abrasive grain, because of the twisting of thecomponent, can be anchored more securely in a make coat applied to anabrasive underlayer. Alternatively or additionally, in many embodiments,swarf which arises in the processing of a surface can be moved betterfrom the surface because of the twisting, such that this swarf does nothinder the abrasive action and evolution of heat is reduced. Moreparticularly, the swarf which arises in the course of grinding can bemoved past the abrasive grain in a better way and therefore does notblock the material removal space in front of the abrasive grain.Alternatively or additionally, in many embodiments, the cross-sectionalarea in contact with a surface being processed can change if thecomponent is being removed gradually. Thus, even if abrasive grain isonly ever being moved in a single direction relative to the surfacebeing processed, the orientation of the cross-sectional area and of theedges and corners that bound it will change with time, which can beadvantageous in some cases. In addition, the abrasive grains, because ofthe twisting, can themselves be oriented on an underlayer in the courseof mechanical application with high probability in such a way that atleast one tip and/or at least one edge of the abrasive grains pointsaway from the underlayer.

At least one geometric elementary body may, for example, be apolyhedron, especially a prism, an antiprism, a pyramid or afrustopyramid. In other embodiments, at least one of the geometricelementary bodies may be a cone, a frustocone or a cylinder.

A cone is generally understood to mean a solid which is bounded by anessentially flat base face and a multitude of essentially straight shellsegments, each point on the outline of the base face being connected toa common point in the cone (the cone tip) by one of the shell segmentsin each case, and the cone tip being outside the plane defined by thebase face. More particularly, the cone may be a pyramid if the base faceis a polygon. From each corner of the base face of such a pyramid, astraight lateral edge of the elementary body extends to the tip of thepyramid and can ensure cutting action. A component in the form of atwisted pyramid has correspondingly twisted lateral edges when the twistaxis runs transverse, especially at right angles, to the base face. Asan alternative to a polygonal base face, however, it is also conceivablethat the base face of the cone has at least one curved section or evenexclusively curved sections.

Analogously to the general definition above, a frustocone is understoodto mean a part of a cone in which the cone tip has been removed by anessentially flat section. More particularly, the frustocone may be afrustopyramid having a polygonal base face. From each corner of the baseface of such a frustopyramid, a lateral edge of the elementary bodyextends to the corresponding corner of the top face and can ensurecutting action. A component in the form of a twisted frustopyramid hascorrespondingly twisted lateral edges if the twist axis runs transverse,especially at right angles, to the base face. In addition, the top faceof the frustopyramid has the same number of edges as the base face,which leads to a further increase in cutting action.

A cylinder is understood here and hereinafter in general terms to mean asolid which is bounded by a base face and a top face, and also by anouter face. The base face and the top face are preferably essentiallyflat and likewise preferably essentially parallel to one another. Theshell face is formed by an array of essentially mutually parallelsegments. If these segments run essentially at right angles to the baseface and the top face, the result is a straight cylinder. However,skewed cylinders are likewise conceivable and are within the scope ofthe invention. The base face of the cylinder may, for example, be apolygon; in this case, the elementary body takes the form of a prismwith straight lateral edges which join corners of the base face and thetop face to one another. A component in the form of a twisted prism hascorrespondingly twisted lateral edges if the twist axis runs transverse,especially at right angles, to the base face. Alternatively, the baseface and a top face of the cylinder may also have a shape selected fromthe group consisting of ellipses, rectangles with rounded corners andlenses (sections of two circles, especially with identical radii).

An antiprism is bounded by exactly two congruent n-edged polygons and 2ntriangles, especially equilateral triangles. At a corner, there isalways a junction of one n-edged polygon and three triangles. The totalnumber of edges in an antiprism is 4n, namely n edges in the base face,n edges in the opposite top face and 2n lateral edges that run betweenthe base face and the top face. A component in the form of a twistedantiprism has correspondingly twisted lateral edges when the twist axisruns transverse, especially at right angles, to the base face.

The abovementioned cones, frustocones, cylinders and antiprisms eachhave an essentially flat base face. Polyhedra, which do not form part ofthis category, likewise contain flat base faces. The reference pointthrough which the twist axis runs may be within this base face,especially in the center of this base face or at the base point of acone or frustocone. The twist axis may extend transverse, especially atright angles, to the base face. If the base face is circular, it ispreferable that the base point does not run through the center of thebase face and/or the twist axis does not extend at right angles to thebase face.

In advantageous embodiments, the abrasive grain contains a base elementhaving a bottom side and an opposite top side which is especiallyparallel to the bottom side, and also at least one top element having abottom side disposed on the top side of the base element. The baseelement and the top element should also preferably be regarded only astheoretical components of the abrasive grain.

The base element and/or at least one top element may form one of thecomponents, i.e. essentially have the shape of a twisted geometricelementary body having one or more of the abovementioned features. Thebottom side of the base element may form the base face of a twistedelementary body, for example the base face of a twisted frustocone.Alternatively or additionally, the bottom side of the top element mayform the base face of a twisted elementary body, for example the baseface of a twisted cone. If both the base element and the top elementform a twisted geometric elementary body, the two twist axes may beparallel to one another and may even coincide.

The shapes of the base element and the top element may be chosenindependently of one another. For example, the base element may take theform of an untwisted frustocone and the top element the form of atwisted prism. Alternatively, the base element may have the shape of atwisted frustopyramid and the top element the shape of an untwistedcircular cylinder. Alternatively, both the base element and the topelement may take the form of twisted cuboids. It is likewise conceivablethat the base element or the top element is neither an elementary bodynor a twisted elementary body, provided that at least one othercomponent of these types has this property.

The bottom side of the base element may form a bottom side of theabrasive grain. If the base element takes the form of a twistedgeometric base element, the base element and hence the entire abrasivegrain can be anchored in a particularly stable manner in a make coatapplied to an abrasive underlayer. For a base element, angledifferentials between the bottom side and top side of about 45° areadvantageous, because this can result in corners of the bottom side ofthe base element projecting beyond the top side of the base element.

A top side of the top element may form a top side of the abrasive grain.In that case, the cross-sectional area in contact with a surface beingprocessed can change if the top element is gradually removed in thecourse of grinding. Thus, even if the abrasive grain is only ever movedin a single direction relative to the surface being processed, therewill nevertheless be a change in the orientation of the cross-sectionalarea with time, which can be advantageous in some cases. Appropriately,the top side of the top element runs parallel to and opposite the bottomside of the base element. This is because, in that case, the top side ofthe top element already runs parallel to a surface being processed atthe start of the grinding process if the bottom side of the base elementlies atop the abrasive underlayer.

In many embodiments, it may be advantageous if the transition regionbetween the base element and top element does not form a sharp edge,since this would result in a disadvantageous force flow. This force flowcould, especially in the case of the preferred ceramic abrasive grains,lead to comparatively easy fracture in this transition region. Instead,the transition region may contain, for example, a rounded and/orchamfered area between the base element and top element; these variantstoo are encompassed by the invention. The extent of the rounded orchamfered area, especially the extent in a plane parallel to the bottomside of the base element and/or at right angles to the bottom side ofthe base element, may be up to ⅕ of the size of the abrasive graindefined below. In some embodiments, the extent of the rounded orchamfered area should be at least 1/15 of the size of the abrasivegrain. In addition, a chamfered or rounded area allows easier removal ofan abrasive grain precursor from a die, for example in a process asdescribed in detail below.

The shape and size of the abrasive grain can be determined, forinstance, with the aid of a microscope. The inventive abrasive grain mayhave a size over the entire size range which is also customary forconventional abrasive grains. Typically, abrasive grains with greatersizes lead to higher material removal from a surface being processedthan smaller abrasive grains. For example, the abrasive grain may have asize in the range from 100 μm to 2000 μm. This size can be determinedexperimentally with the aid of a microscope. It is understood to meanthe diameter of a circle enveloping the microscope image of the abrasivegrain, i.e. the smallest diameter of a circle surrounding the image.

The ratio between the base face diameter and height of the abrasivegrain is preferably in the range from 1:3 to 12:1. In some variants,this ratio is in the range from 1:1 to 10:1 and more preferably in therange from 4:1 to 9:1. The base face diameter is understood here andhereinafter to mean the diameter of a circle enveloping the base face ofthe abrasive grain. This base face may, for example, be theabovementioned base face of a twisted cone, a twisted frustocone or atwisted cylinder. The height of the abrasive grain is understood to meanthe extent of the abrasive grain measured along the twist axis.

If, in one example, the base face is an equilateral triangle with sidelength a, the base face diameter is 2√3/3α. In this case, the ratiobetween side length of the triangle and height of the abrasive grain maybe in the range from 1:3 to 8:1, preferably from 1:1 to 7:1 and morepreferably from 4:1 to 6:1. If, in a second example, the base face is asquare having side length a, the base face diameter is √2α. In this casetoo, the ratio between the side length of the square and the height ofthe abrasive grain may be in the range from 1:3 to 8:1, preferably from1:1 to 7:1 and more preferably from 4:1 to 6:1.

In other variants, the ratio between the base face diameter and heightof the abrasive grain may be in the range from 1:2 to 2:1, furtherpreferably from 1:1.5 to 1.5:1, even further preferably from 1:1.2 to1.2:1. In these variants, in the case of electrostatic application, themaximum possible differences with regard to the maximum extent at rightangles to the underlayer between “upright” and “recumbent” abrasivegrains are much smaller. The advantage of a monomodal abrasive grainsize distribution can be enhanced even further as a result.

The ratio of the length of the base face to the width of the base faceof the abrasive grain is preferably less than 10:1. The length of thebase face is regarded here and hereinafter as the greatest linear extentof the base face. The width of the base face is understood here andhereinafter to mean the extent of the base face measured at right anglesthereto. If the base face is, for example, a rectangle having a longerside and a shorter side, the abovementioned ratio is the same as theratio of these two side lengths. For an elliptical base face, the ratiois equal to the ratio of the two semi-major axes. In some workingexamples, it is preferable when said ratio of length and width is in therange from 10:1 to 10:6, especially from 10:2 to 10:3.

The above-described shape of the abrasive grain is an idealized shape.However, the invention also encompasses abrasive grains which differfrom this idealized shape within the scope of manufacturing tolerances.Possible deviations from the idealized shape may have one or more of thefollowing causes:

-   -   cavities or bubbles caused by enclosed air and/or other gases in        a dispersion from which the abrasive grains are produced;    -   absent corners and/or edges which arise through incomplete        filling of a die and/or during the removal of a precursor of the        abrasive grain from a die; collapsed side faces and/or edges        which arise through shrinkage during the removal of a portion of        the volatile components of the dispersion; especially collapsed        faces which arise from the upper free surface of the dispersion        which is not in contact with the die;    -   material that has flaked away, caused by a drying and/or        sintering process; broken corners and/or edges which arise        through transport and/or during further processing of the        abrasive grains as bulk material.

The deviations from the ideal case need not necessarily lead todisadvantageous properties of the abrasive grain. For example, brokencorners and/or edges may also have the effect that further cutting edgesarise compared to the ideal case, which can even have a positive effecton the abrasive action.

More particularly, the invention also encompasses abrasive grains whoseshape corresponds only essentially to the idealized shape. For example,a point on the surface is regarded as a corner or tip (especially as thetip of a cone) when there is actually curvature at that point, but withradii of curvature of not more than 10%, preferably not more than 5%,more preferably not more than 2%, of the above-defined size of theabrasive grain. In addition, a face, especially a base face, of anelementary body is regarded as essentially flat even if it is dished andhas radii of curvature of at least twice, preferably at least fivetimes, more preferably at least ten times, the size of the abrasivegrain. In addition, untwisted edges of a geometric elementary body inthe shape of a polyhedron, cone, frustocone or cylinder are alsoregarded as linear even when they are at least partly or even entirelycurved but have a radius of curvature of at least twice, preferably atleast five times, more preferably at least ten times, the size of theabrasive grain.

Preferably, however, the abrasive grain has an idealized shape asdescribed above.

The abrasive grain may, for example, comprise or consist of a ceramicmaterial, especially a polycrystalline ceramic material. Preferably, theabrasive grain comprises alumina, more preferably α-Al₂O₃.

Alternatively or additionally, the abrasive grain may also comprise atleast one further metal oxide, for instance sodium oxide, magnesiumoxide, iron oxide, silicon oxide, calcium oxide, zirconium oxide,yttrium oxide, zinc oxide, cobalt oxide, nickel oxide, hafnium oxide,chromium oxide, praseodymium oxide, samarium oxide, ytterbium oxide,neodymium oxide, lanthanum oxide, gadolinium oxide, cerium oxide,dysprosium oxide, erbium oxide, lutetium oxide, titanium oxide,manganese oxide or any desired combinations thereof.

Many of these metal oxides originate from impurities in the startingmaterials, for example in alumina. Given sufficiently low proportions inthe abrasive grain, however, such impurities have no adverse effect onthe production and use of the abrasive grain. Some of these impuritiesmay even have a positive effect on the abrasive grain.

Fractions of zirconium oxide or yttrium oxide may originate, forexample, from grinding balls which can be used in a grinding step in theproduction of the abrasive grains. Fractions of iron oxide may originatefrom a grinding vessel which is used in such a grinding step.

Likewise alternatively or additionally, the abrasive grain may comprisefurther hard substances, for example silicon carbide.

In addition, the abrasive grain may comprise at least one breakdownproduct of a dispersant described in detail hereinafter, which was usedin the production of the abrasive grains. In addition, the abrasivegrain may comprise at least one nucleating agent or breakdown productthereof and/or at least one sintering aid and/or breakdown productthereof which was used in the production of the abrasive grains. Thesintering aid may, for example, be magnesium oxide which has alreadybeen mentioned above.

Moreover, the abrasive grain may also comprise at least one of thefurther substances described in EP 615 816 A1.

The ingredients mentioned can be determined with the aid of chemicalanalysis methods known per se.

The abrasive grain may comprise or consist of a structure having one ormore different phases. A first phase may consist of alumina, morepreferably of α-Al₂O₃. A second phase may consist of one or more of theabovementioned further metal oxides and/or further hard substances.

The proportion of alumina, especially of α-Al₂O₃, in the abrasive grainmay, for example, be at least 25% by weight, preferably at least 50% byweight, further preferably at least 70% by weight, more preferably atleast 95% by weight.

The abrasive grain may have a coating which covers only part of thesurface, especially only one or more edges and/or only one of severalflat areas of the surface. The coating may, for instance, be aferromagnetic or paramagnetic coating. Such a partial coating of thesurface with a ferromagnetic or paramagnetic material enables alignmentof the abrasive grain in a given direction in a magnetic field appliedduring the scattering operation. Alternatively, it may also be a coatingof a material having elevated thermal conductivity or a coating whichenables increased adhesion of the abrasive grain on the abrasiveunderlayer.

A further aspect of the invention relates to a collective of abrasivegrains. A collective of abrasive grains is understood here andhereinafter to mean a coherent collection of abrasive grains. Forexample, this may be a collection of abrasive grains which are presentin a container and are stored and transported as such, for example in asack.

Such a collection of abrasive grains can also be used to produce anabrasive article. A collective of abrasive grains is also regarded asthe entirety of all the abrasive grains present in an abrasive article.

Preferably, the collective of abrasive grains contains at least 20% byweight, preferably at least 50% by weight and more preferably at least90% by weight of inventive abrasive grains as described above. The otherabrasive grains present in the collective may likewise have a definedshape, but one which differs from the inventive shape, or they may nothave a defined shape since they are, for example, broken abrasivegrains. These other abrasive grains present in the collective are alsoreferred to as “support grains”.

It is conceivable and likewise within the scope of the invention thatthe inventive abrasive grains present in the collective are differentfrom one another. For example, the collective of abrasive grains maycontain a first fraction of abrasive grains of a first embodiment of theinvention, and a second fraction of abrasive grains of a secondembodiment of the invention that are different from the first embodimentof the invention. More particularly, the abrasive grains of the firstembodiment of the invention may differ in terms of size and/or shapefrom the abrasive grains of the second embodiment of the invention.

The collective of abrasive grains may consist exclusively of identicalinventive abrasive grains; more particularly, the collective in thatcase has a size distribution in the form of points.

The collective of abrasive grains may essentially have a sizedistribution which corresponds to a size standard customary in theabrasives industry, for example the American National StandardsInstitute (ANSI), the Standards of the Federation of European Producersof Abrasives (FEPA) or the Japanese Industrial Standard (JIS). Forexample, the collective of abrasive grains may essentially have a grainsize of P12, P16, P20, P24, P30, P36, P40, P50, P60, P80, P100, P120,P150, P180, P220, P240, P280, P320, P360, P400, P500, P600, P800, P1000,P1200, P1500, P2000, P2500, P3000 or P5000 according to the FEPAstandard. In this context, a size distribution “essentially” means thatat least 90% by weight, preferably at least 95% by weight, furtherpreferably at least 99% by weight and more preferably all of theabrasive grains in the collective of abrasive grains meet this standard.

As already described above, it is also conceivable that the collectivecontains at least two different fractions of inventive abrasive grainsand/or at least one fraction of noninventive abrasive grains. Each ofthese fractions may itself have a size distribution corresponding ineach case to one of the abovementioned size standards customary in theabrasives industry.

An inventive abrasive grain or an inventive collective of abrasivegrains can be produced, for example, by the following process known fromU.S. Pat. No. 5,201,916:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. introducing the dispersion into at least one depression of a        die;    -   c. optionally squeegeeing an upper face of the die in order to        remove at least a portion of the dispersion which stands above        the upper face of the die;    -   d. removing a portion of the volatile components of the        dispersion, so as to form at least one abrasive grain precursor;    -   e. removing the abrasive grain precursor from the die;    -   f. optionally calcining the abrasive grain precursor;    -   g. sintering the abrasive grain precursor in order to obtain at        least one abrasive grain.

Before and/or during the production of the dispersion in step a), theraw materials, especially α-alumina particles and/or particles that canbe converted to α-alumina, are ground.

This can be effected, for example, with the aid of a ball mill,especially with the aid of a planetary ball mill.

The dispersion may comprise at least one dispersant. Such a dispersantfacilitates the formation of the dispersion and increases the stabilitythereof by, for example, forming layers around the individual grainswhich prevent lump formation. The dispersant may, for example, be apolymer. In general, the dispersant breaks down during the sintering instep g) if not earlier.

For production of the inventive abrasive grains, it is possible to use acasting mold, said casting mold comprising at least one die having atleast one depression having a particular surface, the surface beingcomplementary to the shape of at least a portion of the surface of theabrasive grain.

The die may comprise or consist of silicone, for example. Thedepressions may have an open top face through which the dispersion canbe introduced. The depressions in the die each have a surface whoseshape is complementary to the shape of at least one portion of thesurface of the desired abrasive grain. For example, it may becomplementary to the part of the surface of the abrasive grain that doesnot form the bottom side of a base element. As a result of theproduction, this bottom side may then be dished to a certain degree.

The at least one depression may be coated, for example with Teflon. Thiscan facilitate the introduction of the dispersion in step b) and theremoval of the abrasive grain precursor in step e).

The precursor formed in step d) should preferably have sufficientmechanical stability to be further processible as bulk material in thesubsequent steps. The optional calcining in step f) is advantageous oreven required especially when the dispersion comprises a plurality ofdifferent raw materials and a phase transformation is required.

In a development of the process known from U.S. Pat. No. 5,201,916, forsome abrasive grains, the abovementioned die can advantageously only beone part of a multipart casting mold which additionally comprises atleast one shaping element, especially a further die or a ram elementwith which, in addition to the surface shaped in the first die, at leasta portion of the remaining surface of the abrasive grain can be shaped.

Preferably, the ram elements do not completely close off the depressionsof the die, such that the volatile component of the dispersion canescape.

More complicated shapes of abrasive grains can be shaped in dies thatcan be assembled, in a similar manner to injection molding processes.For this purpose, at least one die has at least one introduction openingthrough which the dispersion can get into the depressions.

Alternatively, many of the inventive abrasive grains can be producedwith the aid of an extrusion process. This is especially true ofabrasive grains which consist of a single element which at leastessentially has the shape of a twisted cylinder, especially of a twistedprism (for example a twisted cuboid with rectangular base face and topface) or of a twisted cylinder with elliptical base face and top face.The production of abrasive grains in the form of untwisted prisms withthe aid of an extrusion process is known from WO 2012/092605 A2.

The extrusion process comprises the following steps:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. extruding the dispersion through an exit orifice of a nozzle,        the exit orifice having at least essentially the shape of a        twisted cylinder, such that an extrudate is obtained;    -   c. severing the extrudate to obtain abrasive grain precursors;    -   d. optionally calcining the abrasive grain precursors;    -   e. sintering the abrasive grain precursors in order to obtain at        least one abrasive grain.

The extrusion of plastic ceramic compositions per se is known to thoseskilled in the art and is described, for example, in section 7.3.2.2.2of Salmang, Scholze, Telle: Keramik [Ceramics], Springer, 7th edition.

The configuration of the exit orifice of the nozzle allows theproduction of abrasive grains in the form of twisted cylinderscomplementary to the shape of the exit orifice. Analogously to the abovedefinition, there is thus a theoretical twist axis which runs throughthe exit orifice. The cross sections of the exit orifice that run atright angles to the twist axis are twisted about the twist axis by anangle relative to a theoretical cylinder, this angle being dependent onthe distance of the cross section from a reference point on the twistaxis, and this dependence preferably being linear.

The cross-sectional area of the exit orifice of the nozzle determinesthe base face of the twisted cylinder. If the cross-sectional area, forexample, is polygonal, the twisted cylinder will be a twisted prism.With an elliptical cross-sectional area, abrasive grains can be producedin the form of a twisted cylinder with an elliptical base face.Analogously to the above-described size figures for the base face of theabrasive grains, the cross-sectional area of the exit orifice may alsobe assigned a base face diameter, a length and a width. The ratio oflength and width of the cross-sectional area of the exit orificedetermines the ratio of length and width of the base face of theabrasive grains.

The severing in step c can be effected, for example, with the aid of ablade, especially a rotating blade. The distances at which the extrudateis severed determines the above-defined height of the abrasive grains.

The dispersion produced or provided in step a) of the extrusion processmay further comprise at least one organic additive. The organic additivemay, for instance, be a plasticizing agent with which the dispersion canbe made extrudable, especially by imparting a viscosity suitable forextrusion thereto. The organic additive may also be a binder with whichthe strength of the abrasive grain precursor can be increased.

Between step c) and the optional step d), the organic additive mentionedcan be burnt out. For this purpose, it can be brought to a suitabletemperature for a suitable period. Suitable periods of time andtemperatures are known to those skilled in the art or can at least beascertained by routine tests. For example, the organic additive can beburnt out for 2 h to 4 h at 350° C. to 450° C.

In a further alternative, at least some of the inventive abrasive grainscan also be produced by a process comprising the following steps:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. producing a film from the dispersion;    -   c. severing the film produced in step b) to form film sections;    -   d. shaping the film sections produced in step c) to obtain        abrasive grain precursors;    -   e. optionally calcining the abrasive grain precursors;    -   f. sintering the abrasive grain precursors in order to obtain at        least one abrasive grain.

The film can be produced in step b), for example, by a film drawing orfilm casting method known per se. Film casting is known to those skilledin the art and is described, for example, in section 7.3.2.1.3 ofSalmang, Scholze, Telle: Keramik, Springer, 7th edition. The shaping instep d) can be achieved, for instance, by embossing.

The dispersion produced or provided in step a) of the process describedlast may further comprise at least one organic additive as well. Theorganic additive may, for instance, be a plasticizing agent with which asuitable viscosity can be imparted to the dispersion. The organicadditive may also be a binder with which the strength of the abrasivegrain precursor can be increased.

Between step d) and the optional step e) of the process described last,the organic additive mentioned can be burnt out. For this purpose, itcan be brought to a suitable temperature for a suitable period. Suitableperiods of time and temperatures are known to those skilled in the artor can at least be ascertained by routine tests. For example, theorganic additive can be burnt out for 2 h to 4 h at 350° C. to 450° C.

Another aspect of the invention relates to an abrasive articlecontaining a collective of abrasive grains as described above. Moreparticularly, it is thus possible for at least 20% by weight, preferablyat least 50% by weight, more preferably at least 90% by weight, of allthe abrasive grains of the abrasive article to take the form ofinventive abrasive grains as described above. The other abrasive grainsmay likewise have a defined shape, but one which differs from theinventive shape, or they may not have a defined shape.

The abrasive article may, for example, be a coated abrasive article, anabrasive article web, a bonded abrasive article or an abrasive brush.

A coated abrasive article comprises an underlayer, especially a flexibleunderlayer, for example paper, vulcanized fiber, a film, a textilematerial, a foam or multilayer combinations thereof. The abrasive grainscan be secured to the underlayer with the aid of a base binder (“makecoat”). The make coat and the abrasive grains may be covered with a topbinder (“size coat”). Optionally, above the size coat mentioned, it isalso possible for a second top binder (“supersize coat”) to be present.

The make coat, size coat and supersize coat used may be any bindersknown per se, for example composed of synthetic resin, for instance aphenolic resin, an epoxide, a urea resin, a melamine resin or anunsaturated polyester resin. The size coat and/or supersize coat mayadditionally comprise further customary active ingredients and/orfillers.

The abrasive article may be in different product forms, for example asan abrasive disk or as an abrasive belt.

The invention also encompasses a process for producing an inventiveabrasive article as described above. The process comprises a step inwhich a collective of abrasive grains is fixed on and/or in a substrate,especially by means of a binder. The substrate may, for instance, be anunderlayer, especially a flexible underlayer, of a coated abrasivearticle, a web material for an abrasive web, a matrix for a bondedabrasive or bristle for an abrasive brush. In the case of a coatedabrasive article, the make coat and/or the abrasive grains and/or thesize coat and/or supersize coat can be applied by a method known per se.For example, the abrasive grains can be applied by electrostatic ormechanical means (i.e. by gravimetric means).

In addition, the invention is also directed to a process for grinding asurface with a grinding article as described above. The surface mayespecially be a painted surface. In the case of a painted surface,abrasive grains having sizes of 500 μm or less are particularlysuitable.

The object is additionally achieved by an abrasive grain having at leastsix faces, wherein at least one of the faces has concave curvature.Concave curvature is curvature in the inward direction, i.e. into thebody. In the case of an abrasive grain having a face with such concavecurvature, it is necessarily the case that a corner and/or edge with anacute angle between converging faces must occur elsewhere, for exampleat the edge of the curved face, and/or that a convex curvature withsmaller radii of curvature than would be the case without the inventiveconcave curvature must be present elsewhere.

Preferably, the at least one concave face has two curvatures indifferent three-dimensional directions. The two curvatures arepreferably both concave, such that the face has at least one point whichprojects particularly far into the body.

The acute corners and/or edges which are implicitly present as a resultof the concave curvature generally point in several three-dimensionaldirections. Especially in the case of mechanical scattering of theabrasive grains on an underlayer, the result is therefore a randomdistribution of the orientations of the abrasive grains, in which asufficient number of acute corners and/or edges point away from theunderlayer.

Solids having concave faces are comparatively easy to produce. It ispossible, for example, to provide a correspondingly convex depression ina die, into which a dispersion as described in detail further down isintroduced.

It is also possible to provide a starting composition, especially adispersion as described further down, in such a way that a castinghaving flat faces or faces curved only in one direction contracts in thecourse of drying, or in the course of escape of the volatile component,in such a way that the faces curve inward.

The object is also achieved by an abrasive grain, especially asdescribed above, wherein the abrasive grain has a structure with atleast one reentrant corner.

The corner may be a point on the surface of the body at which edgesmeet, or a tip at which a dished face comes to a point, for example thepoint of a cone or droplet.

A reentrant corner is understood to mean a corner for which there is atangential area which can be used to define a circle having the corneras its center, the circumference of which is completely within thesolid.

A solid having a reentrant corner is, just like the solid having aconcave face, not a convex solid. Both kinds of solids have “dents”.

For the solid having a reentrant corner too, it is necessarily the casethat corners and/or edges with an acute angle between converging facesmust occur elsewhere, for example at the edge of the “dent”, and/or thata convex curvature with smaller radii of curvature than would be thecase without the inventive reentrant corner must be present elsewhere.These implicitly present acute corners and/or edges point in severalthree-dimensional directions. Especially in the case of mechanicalscattering of the abrasive grains on an underlayer, the result istherefore a random distribution of the orientations of the abrasivegrains, in which a sufficient number of acute corners and/or edges pointaway from the underlayer.

In an advantageous execution of the invention, an abrasive grain havinga shape as described above additionally has at least one curved edge,especially a concave edge.

The corners that arise at converging concave edges are more acute thanthe corners that are formed by corresponding straight edges.

These acute corners that implicitly exist also contribute to improvedcutting capacity of the abrasive grain.

In a further advantageous execution, the abrasive grain takes the formof a solid having corners, wherein at least some of the corners,especially all the convex corners, correspond to the corners of a convexpolyhedron, especially a Platonic solid, an Archimedean solid, a Catalansolid, a prism, an antiprism, or a Platonic solid, Archimedean solid,Catalan solid, prism or antiprism with linear distortion.

A convex corner is understood here to mean a corner on the surface ofthe solid which does not lie on a connecting line between two points onthe solid.

The solid shape of the abrasive grain then arises on the basis of simplegeometric solids, namely complex polyhedra, having “dents” or recesses,either in the form of inward curvature or of a reentrant corner. Solidsof this kind usually have a multitude of features of symmetry, such thata number of equivalent alignments on an underlayer arise for theindividual solids.

In the case of scattering of abrasive grains on an underlayer, asufficiently large number of acute edges and/or corners point in thegrinding direction.

Platonic solids are those convex polyhedra whose lateral faces are allmutually congruent regular polygons, any number of which converge atevery corner. The Platonic solids include the tetrahedron, octahedronand icosahedron, each of which have equilateral triangles as lateralfaces, the hexagon or cube, which have squares as lateral faces, and thedodecahedron with equilateral pentagons as lateral faces.

The Archimedean solids are convex polyhedra having lateral faces thatare regular polygons. The characteristic property of the Archimedeansolids is that all the corners of the solid are entirely identical withrespect to one another.

Prisms, antiprisms and the five Platonic solids are not counted amongthe Archimedean solids.

The Archimedean solids especially include the Platonic solids havingcapped corners (frusto-tetrahedron, -hexahedron, -octahedron,-dodecahedron and -icosahedron).

A prism is bounded by exactly two congruent n-edged polygons and nparallelograms. The n-edged polygons may especially be regular n-edgedpolygons. Said parallelograms are rectangles, especially squares, in thecase of a straight prism. Such a prism exists for every natural number ngreater or equal to three. At any corner, one n-edged polygon and twoparallelograms always meet.

An antiprism is bounded by exactly two congruent n-edged polygons and 2ntriangles, especially equilateral triangles. Such an antiprism existsfor every natural number n greater than or equal to three. At anycorner, one n-edged polygon and three triangles always meet.

The Catalan solids have only one kind of face, namely identicalirregular polygons, but have at least two different kinds of corners.

In a Platonic solid, Archimedean solid, Catalan solid, prism orantiprism with linear distortion, i.e. with compression or extensionalong at least one axis, especially an axis of symmetry, not allsymmetries are maintained compared to the undistorted form. Since theseforms, however, have a multitude of features of symmetry, thelinear-distorted corresponding solid will always have a number offeatures of symmetry. A cuboid, for example, is a linear-distorted cubewhich has fewer features of symmetry that a cube but still has a largenumber of regular features.

More particularly, the “dents” or recesses are on all the faces of theconvex polyhedron, or preferably on all the faces except for a contactface. On the side of the solid facing the contact face, the lack of arecess there causes more material to be accumulated, such that anabrasive grain, when scattered on an underlayer, falls preferentiallyonto this face. The more acute corners and/or edges then point away fromthe underlayer.

Simple geometric solids having a recess can be produced reproducibly ina comparatively undemanding manner.

The shape and size of the abrasive grain can be determined, forinstance, with the aid of a microscope. The inventive abrasive grain mayhave a size over the entire size range which is also customary forconventional abrasive grains. Typically, abrasive grains with greatersizes lead to higher material removal from a surface being processedthan smaller abrasive grains. For example, the abrasive grain may have asize in the range from 100 μm to 2000 μm. This size can be determinedexperimentally with the aid of a microscope. It is understood to meanthe diameter of a circle enveloping the microscope image of the abrasivegrain, i.e. the smallest diameter of a circle surrounding the image.

The above-described shape of the abrasive grain is an idealized shape.However, the invention also encompasses abrasive grains which differfrom this idealized shape within the scope of manufacturing tolerances.Possible deviations from the idealized shape may have one or more of thefollowing causes:

-   -   cavities or bubbles caused by enclosed air and/or other gases in        a dispersion from which the abrasive grains are produced;    -   absent corners and/or edges which arise through incomplete        filling of a die and/or during the removal of a precursor of the        abrasive grain from a die;    -   collapsed side faces and/or edges which arise through shrinkage        during the removal of a portion of the volatile components of        the dispersion; especially collapsed faces which arise from the        upper free surface of the dispersion which is not in contact        with the die;    -   material that has flaked away, caused by a drying and/or        sintering process;    -   broken corners and/or edges which arise through transport and/or        during further processing of the abrasive grains as bulk        material.

The deviations from the ideal case need not necessarily lead todisadvantageous properties of the abrasive grain. For example, brokencorners and/or edges may also have the effect that further cutting edgesarise compared to the ideal case, which can even have a positive effecton the abrasive action.

More particularly, the invention also encompasses abrasive grains whoseshape corresponds only essentially to the idealized shape. A point onthe outline is essentially regarded as a corner when the radius ofcurvature at that point is not more than 15%, preferably not more than10%, more preferably not more than 5%, particularly preferably not morethan 2%, of the diameter of the abrasive grain.

Preferably, however, the abrasive grain has an idealized shape asdescribed above.

The abrasive grain may, for example, comprise or consist of a ceramicmaterial, especially a polycrystalline ceramic material. Preferably, theabrasive grain comprises alumina, more preferably α-Al₂O₃.

Alternatively or additionally, the abrasive grain may also comprise atleast one further metal oxide, for instance sodium oxide, magnesiumoxide, iron oxide, silicon oxide, calcium oxide, zirconium oxide,yttrium oxide, zinc oxide, cobalt oxide, nickel oxide, hafnium oxide,chromium oxide, praseodymium oxide, samarium oxide, ytterbium oxide,neodymium oxide, lanthanum oxide, gadolinium oxide, cerium oxide,dysprosium oxide, erbium oxide, lutetium oxide, titanium oxide,manganese oxide or any desired combinations thereof.

Many of these metal oxides originate from impurities in the startingmaterials, for example in alumina. Given sufficiently low proportions inthe abrasive grain, however, such impurities have no adverse effect onthe production and use of the abrasive grain. Some of these impuritiesmay even have a positive effect on the abrasive grain.

Fractions of zirconium oxide or yttrium oxide may originate, forexample, from grinding balls which can be used in a grinding step in theproduction of the abrasive grains. Fractions of iron oxide may originatefrom a grinding vessel which is used in such a grinding step.

Likewise alternatively or additionally, the abrasive grain may comprisefurther hard substances, for example silicon carbide.

In addition, the abrasive grain may comprise at least one breakdownproduct of a dispersant described in detail hereinafter, which was usedin the production of the abrasive grains. In addition, the abrasivegrain may comprise at least one nucleating agent or breakdown productthereof which was used in the production of the abrasive grains. Thenucleating agent may, for example, be magnesium oxide which has alreadybeen mentioned above.

Moreover, the abrasive grain may also comprise at least one of thefurther substances described in EP 615 816 A1.

The ingredients mentioned can be determined with the aid of chemicalanalysis methods known per se.

The abrasive grain may comprise or consist of a structure having one ormore different phases. A first phase may consist of alumina, morepreferably of α-Al₂O₃. A second phase may consist of one or more of theabovementioned further metal oxides and/or further hard substances.

The proportion of alumina, especially of α-Al₂O₃, in the abrasive grainmay, for example, be at least 25% by weight, preferably at least 50% byweight, further preferably at least 70% by weight, more preferably atleast 95% by weight.

The abrasive grain may have a coating which covers only part of thesurface, especially only one or more edges and/or only one of severalflat areas of the surface. The coating may, for instance, be aferromagnetic or paramagnetic coating. Such a partial coating of thesurface with a ferromagnetic or paramagnetic material enables alignmentof the abrasive grain in a given direction in a magnetic field appliedduring the scattering operation. Alternatively, it may also be a coatingof a material having elevated thermal conductivity or a coating whichenables increased adhesion of the abrasive grain on the abrasiveunderlayer.

A further aspect of the invention relates to a collective of abrasivegrains. A collective of abrasive grains is understood here andhereinafter to mean a coherent collection of abrasive grains. Forexample, this may be a collection of abrasive grains which are presentin a container and are stored and transported as such, for example in asack.

Such a collection of abrasive grains can also be used to produce anabrasive article. A collective of abrasive grains is also regarded asthe entirety of all the abrasive grains present in an abrasive article.

Preferably, the collective of abrasive grains contains at least 20% byweight, preferably at least 50% by weight and more preferably at least90% by weight of inventive abrasive grains as described above. The otherabrasive grains present in the collective may likewise have a definedshape, but one which differs from the inventive shape, or they may nothave a defined shape since they are, for example, broken abrasivegrains. These other abrasive grains present in the collective are alsoreferred to as “support grains”.

It is conceivable and likewise within the scope of the invention thatthe inventive abrasive grains present in the collective are differentfrom one another. For example, the collective of abrasive grains maycontain a first fraction of abrasive grains of a first embodiment of theinvention, and a second fraction of abrasive grains of a secondembodiment of the invention that are different from the first embodimentof the invention. More particularly, the abrasive grains of the firstembodiment of the invention may differ in terms of size and shape fromthe abrasive grains of the second embodiment of the invention.

The collective of abrasive grains may consist exclusively of identicalinventive abrasive grains; more particularly, the collective in thatcase has a size distribution in the form of points.

The collective of abrasive grains may essentially have a sizedistribution which corresponds to a size standard customary in theabrasives industry, for example the American National StandardsInstitute (ANSI), the Standards of the Federation of European Producersof Abrasives (FEPA) or the Japanese Industrial Standard (JIS). Forexample, the collective of the abrasive grains may essentially have agrain size of P12, P16, P20, P24, P30, P36, P40, P50, P60, P80, P100,P120, P150, P180, P220, P240, P280, P320, P360, P400, P500, P600, P800,P1000, P1200, P1500, P2000, P2500, P3000 or P5000 according to the FEPAstandard. In this context, a size distribution “essentially” means thatat least 90% by weight, preferably at least 95% by weight, furtherpreferably at least 99% by weight and more preferably all of theabrasive grains in the collective of abrasive grains meet this standard.

As already described above, it is also conceivable that the collectivecontains at least two different fractions of inventive abrasive grainsand/or at least one fraction of noninventive abrasive grains. Each ofthese fractions may itself have a size distribution corresponding ineach case to one of the abovementioned size standards customary in theabrasives industry.

An inventive abrasive grain or an inventive collective of abrasivegrains can be produced, for example, by the following process known fromU.S. Pat. No. 5,201,916:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. introducing the dispersion into at least one depression of a        die;    -   c. optionally squeegeeing an upper face of the die in order to        remove at least a portion of the dispersion which stands above        the upper face of the die;    -   d. removing a portion of the volatile components of the        dispersion, so as to form at least one abrasive grain precursor;    -   e. removing the abrasive grain precursor from the die;    -   f. optionally calcining the abrasive grain precursor;    -   g. sintering the abrasive grain precursor in order to obtain at        least one abrasive grain.

Before and/or during the production of the dispersion in step a), theraw materials, especially α-alumina particles and/or particles that canbe converted to α-alumina, are ground. This can be effected, forexample, with the aid of a ball mill, especially with the aid of aplanetary ball mill.

The dispersion may comprise at least one dispersant. Such a dispersantfacilitates the formation of the dispersion and increases the stabilitythereof by, for example, forming layers around the individual grainswhich prevent lump formation. The dispersant may, for example, be apolymer. In general, the dispersant breaks down during the sintering instep g) if not earlier.

For production of the inventive abrasive grains, it is possible, asdescribed above, to use a casting mold, said casting mold comprising atleast one die having at least one depression having a particularsurface, the surface being complementary to the shape of at least partof the surface of the abrasive grain.

Preferably, there is a multitude of depressions in the die, and so it ispossible with one casting operation to cast a multitude of abrasivegrain bodies.

In a development of the process known from U.S. Pat. No. 5,201,916, theabovementioned die is advantageously just one part of a multipartcasting mold which additionally comprises at least one shaping element,especially a further die or a ram element with which, in addition to thesurface shaped in the first die, at least a portion of the remainingsurface of the abrasive grain can be shaped.

For example, ram elements may be provided, which are guided into thefilled depressions of the first die, which results, for example, inaccordance with the invention, in “dents”, namely concave curvaturesand/or reentrant corners, in the bodies of the abrasive grains.

Preferably, the ram elements do not completely close off the depressionsof the die, such that the volatile component of the dispersion canescape.

More complicated shapes of abrasive grain bodies can be shaped in diesthat can be assembled, in a similar manner to injection moldingprocesses. For this purpose, at least one die has at least oneintroduction opening through which the dispersion can get into thedepressions.

The die and/or the ram element may comprise or consist of silicone, forexample. The depressions may have an open top face through which thedispersion can be introduced.

The depressions in the die each have a surface whose shape iscomplementary to the shape of at least one portion of the surface of thedesired abrasive grain.

Preferably, the die has depressions complementary to at least a portionof a convex polyhedron, especially of a Platonic solid, an Archimedeansolid, a Catalan solid, a prism, an antiprism, or a Platonic solid,Archimedean solid, Catalan solid, prism or antiprism with lineardistortion.

Preferably, the casting mold also has at least one ram element having atleast one convex surface and/or at least one convex corner. Such a ramelement can be used to shape correspondingly concave faces or reentrantcorners of the abrasive grain body.

Preferably, a dispersion is poured into a die having a multitude ofdepressions and then shaping is undertaken with a ram plate having ramelements, the dispersion present in each depression being shaped by oneram element in the ram plate.

Additionally or alternatively, the depressions of the die may haveconvex faces, convex corners and/or convex edges with whichcorrespondingly concave faces, reentrant corners and/or concave edges ofthe abrasive grain body can be shaped.

The casting mold may also comprise dies having only depressions withplanar faces. Concave surfaces then arise, for example, in step d) whenthe volatile component of the dispersion is removed in such a way thatshrinkage of the precursor takes place.

The precursor that forms in step d) should preferably be of sufficientmechanical stability to be further processible as bulk material in thesubsequent steps. The optional calcining in step f) is advantageous oreven required especially when the dispersion comprises a plurality ofdifferent raw materials and a phase transformation is required.

Another aspect of the invention relates to an abrasive articlecontaining a collective of abrasive grains as described above. Moreparticularly, it is thus possible for at least 20% by weight, preferablyat least 50% by weight, more preferably at least 90% by weight, of allthe abrasive grains of the abrasive article to take the form ofinventive abrasive grains as described above. The other abrasive grainsmay likewise have a defined shape, but one which differs from theinventive shape, or they may not have a defined shape.

The abrasive article may, for example, be a coated abrasive article, anabrasive article web, a bonded abrasive article or an abrasive brush.

A coated abrasive article comprises an underlayer, especially a flexibleunderlayer, for example paper, vulcanized fiber, a film, a textilematerial, a foam or multilayer combinations thereof. The abrasive grainscan be secured to the underlayer with the aid of a base binder (“makecoat”). The make coat and the abrasive grains may be covered with a topbinder (“size coat”). Optionally, above the size coat mentioned, it isalso possible for a second top binder (“supersize coat”) to be present.

The make coat, size coat and supersize coat used may be any bindersknown per se, for example composed of synthetic resin, for instance aphenolic resin, an epoxide, a urea resin, a melamine resin or anunsaturated polyester resin. The size coat and/or supersize coat mayadditionally comprise further customary active ingredients and/orfillers.

The abrasive article may be in different product forms, for example asan abrasive disk or as an abrasive belt.

The invention also encompasses a process for producing an inventiveabrasive article as described above. The process comprises a step inwhich a collective of abrasive grains is fixed on and/or in a substrate,especially by means of a binder. The substrate may, for instance, be anunderlayer, especially a flexible underlayer, of a coated abrasivearticle, a web material for an abrasive web, a matrix for a bondedabrasive or bristle for an abrasive brush. In the case of a coatedabrasive article, the make coat and/or the abrasive grains and/or thesize coat and/or supersize coat can be applied by a method known per se.For example, the abrasive grains can be applied by electrostatic ormechanical means (i.e. by gravimetric means). Because of the inventiveshape of the abrasive grains, even in the case of mechanical scattering,a high proportion of the abrasive grains will be oriented such that theabove-described advantage accrues. It is thus possible to dispense withmore complex electrostatic scattering.

In addition, the invention is also directed to processes for grinding asurface with a grinding article as described above. The surface mayespecially be a painted surface. In the case of a painted surface,abrasive grains having sizes of 500 μm or less are particularlysuitable.

The object is also achieved by an abrasive grain in the form of acylinder having two opposite base faces, the base faces in accordancewith the invention having an outline containing at least one concavesection.

A cylinder is understood here and hereinafter to mean a solid which isbounded by two base faces and by a shell face. These base faces arepreferably essentially flat and likewise preferably essentially parallelto one another. The shell face is formed by an array of essentiallyparallel segments which are referred to hereinafter by the term “shellsegment”. The outline of the base face may comprise at least one linearand/or at least one curved section; the shape of the base faces is thus,more particularly, not restricted to polygons or circles. Moreover, itis also conceivable and within the scope of the invention that the baseface has at least one orifice. In this case, the base face also has aninner outline which may have one or more coherent sections. Thecorresponding shell segments then enclose one or more channels whichfully penetrate the abrasive grain. If the base face is a polygon, theabrasive grain has the shape of a prism. In some variants, it is alsoconceivable that the abrasive grain contains at least one blind holewhich will only partly penetrates the abrasive grain. Such a blind holemay open into one of the base faces or the shell face.

Preferably, the cylinder is a straight cylinder; this means that theshell segments run essentially at right angles to the base faces.However, the invention also equally covers skewed cylinders in which theshell segments do not run at right angles to the base faces.

A section of the outline is understood to be concave in the context ofthe present invention when the linear line connecting the end points ofthis section runs entirely outside the base face. A concave section isespecially regarded as a section having strictly concave curvature.Moreover, a section that consists of two adjacent linear componentsections which meet at a reflex corner is also regarded as concave inthe context of the invention. By definition, a reflex angle is greaterthan 180°.

The effect of the presence of a concave section is that the angle ofengagement is reduced compared to the angle of engagement of aconventional abrasive grain without concave section when the abrasivegrain is used for processing of a surface. As a result, the cuttingaction of the abrasive grain can be increased. This is true particularlywhen the shell segments run parallel to the underlayer—thus, in the caseof a straight cylinder, when the base faces are aligned essentially atright angles to the underlayer. Such an alignment can especially beeffected with the aid of electrostatic scattering of the abrasivegrains, which is known per se.

The outline may also have a plurality of concave sections, especially atleast two or even at least three concave sections. These concavesections may be identical or else different. More particularly, they mayhave identical or different curvatures.

The outline of the base face may have at least one corner. A corner canbe regarded as a point in the outline at which the directions of thetangents to the outline run discontinuously. The shell segment whichends at a corner forms an edge of the abrasive grain which leads toincreased cutting action of the abrasive grain when it comes intocontact with a surface being processed.

The outline defines an internal angle of the base face at a corner. Thisinternal angle is preferably in the range from 65° to 120°, preferablyfrom 65° to 115°, further preferably from 75° to 105°, more preferablyfrom 85° to 95° and is most preferably 90°. Such internal angles lead toparticularly high cutting action.

In many embodiments, the outline contains at least one linear section.The part of the array of shell segments that runs through this linearsection of the outline forms a flat face. In some possible executions,an abrasive grain can be fixed stably on an underlayer when this flatface rests on the underlayer. In other working examples, the flat facemay run essentially parallel to and be in contact with a surface beingprocessed. Such a flat contact of the abrasive grain with the surfacebeing processed can prevent the abrasive grain from tipping.

It is conceivable and within the scope of the invention that a concavesection and a linear section have a common end point without thepresence of a corner here; the directions of the tangents thus runcontinuously here. However, it is preferable in many working exampleswhen at least one end point of a linear section forms a corner in theoutline. If, for example, the linear section is aligned parallel to andis in contact with a surface being processed in the course ofprocessing, the part of the array of shell segments that runs throughthe adjacent section forms a cutting face which runs at an angle to theunderlayer. A cutting face in such an arrangement leads to increasedcutting action, while the flat contact of the abrasive grain with thesurface being processed already mentioned above prevents the abrasivegrain from tipping.

The effect just described can be enhanced when the abrasive grain isformed such that it will be oriented on the underlayer with highprobability in the course of scattering in such a way that at least onelinear section of the outline runs parallel to the underlayer and hencealso to the surface being processed. This can be achieved by virtue ofat least one linear section running at an angle to a support plane ofthe abrasive grain of not more than 20°, preferably not more than 10°,more preferably not more than 5°. More preferably, this angle should be0°, such that the linear section and the support plane run parallel toone another. This support plane is an imaginary plane of the abrasivegrain having the following property: if the support grain is placed ontoa horizontal contact plane in such a way that the support planecorresponds to the contact plane, the abrasive grain is stable againsttipping over. This is the case when the perpendicular projection of thecenter of the abrasive grain onto the contact points lies within theconvex shell of the points at which the abrasive grain rests on thecontact plane. Thus, if the support plane of the abrasive grain lies ona flat abrasive underlayer, the abovementioned angle between the supportplane and linear section is equal to the angle that the linear sectionforms with the underlayer. This is consequently also equal to the anglebetween the linear section and a surface being processed.

Particularly advantageously, a tangent to at least one point on theoutline runs at an angle to a perpendicular that runs at right angles tothe above-described support plane of the abrasive grain. This angle maybe in the range from −30° to +30°, preferably from −25° to +25°, furtherpreferably from −15° to +15°, more preferably from −5° to +5°, and mostpreferably 0°. As above, this angle is also regarded as positive whenthe perpendicular runs within the abrasive grain; it is regarded asnegative where it runs outside the abrasive grain. If the support planeof the abrasive grain rests on an abrasive underlayer, the magnitude ofthis angle corresponds to the angle of engagement of a cutting face inthe region of this point. The smaller the magnitude of the angle ofengagement, the less change there is in the size of the surface of theabrasive grain that gets into contact with the surface being processedas the abrasive grain is worn away, and the more constant is theabrasive action during the wear.

At least one end point of the concave section may form a corner of theoutline. More particularly, this corner may also simultaneously be anend point of a straight section of the outline.

In preferred working examples, the outline has at least three and morepreferably exactly three concave sections whose respective ends arecorners of the outline. In addition, the outline preferably has a linearsection between any two concave sections. The concave sections may, forexample, have concave curvature. The linear sections may have equallengths. The three concave sections may also have the same lengths asone another. More particularly, the base face may thus have three-foldsymmetry. Three-fold symmetry means that the shape and hence the actionof the abrasive grain is independent of the orientation in which theabrasive grain lies on the underlayer. Four-fold, five-fold, six-foldsymmetries etc. also lead to this independence.

The shape and size of the abrasive grain can be determined, forinstance, with the aid of a microscope. The inventive abrasive grain mayhave a size over the entire size range which is also customary forconventional abrasive grains. Typically, abrasive grains with greatersizes lead to higher material removal from a surface being processedthan smaller abrasive grains. For example, the abrasive grain may have asize in the range from 100 μm to 2000 μm. The diameter of the abrasivegrain is understood here to mean the diameter of a circle enveloping thebase face. This is the smallest diameter of a circle which surrounds theabrasive grain. To determine the diameter, with the aid of a microscope,an image of a base face of the abrasive grain can be produced. Thediameter (i.e. the diameter of the enveloping circle) can then bedetermined from this image.

The ratio of the height of the abrasive grain and the diameter ispreferably not more than 1, further preferably not more than 0.8 andmore preferably not more than 0.6. The height of the abrasive grain isunderstood to mean the vertical distance between the two base faces. Thesmaller this ratio, the narrower the shell faces of the abrasive grainfor a given diameter and the smaller the friction and the evolution ofheat when the abrasive grain is disposed on an underlayer with anopposite shell face.

The above-described shape of the abrasive grain is an idealized shape.However, the invention also encompasses abrasive grains which differfrom this idealized shape within the scope of manufacturing tolerances.Possible deviations from the idealized shape may have one or more of thefollowing causes:

-   -   cavities or bubbles caused by enclosed air and/or other gases in        a dispersion from which the abrasive grains are produced;    -   absent corners and/or edges which arise through incomplete        filling of a die and/or during the removal of the precursor of        the abrasive grain from the die;    -   collapsed side faces and/or edges which arise through shrinkage        during the removal of a portion of the volatile components of        the dispersion; especially collapsed faces which arise from the        upper free surface of the dispersion which is not in contact        with the die;    -   material that has flaked away, caused by a drying and/or        sintering process;    -   broken corners and/or edges which arise through transport and/or        during further processing of the abrasive grains as bulk        material.

The deviations from the ideal case need not necessarily lead todisadvantageous properties of the abrasive grain. For example, brokencorners and/or edges may also have the effect that further cutting edgesarise compared to the ideal case, which can even have a positive effecton the abrasive action.

More particularly, the invention also encompasses abrasive grains whoseshape corresponds only essentially to the idealized shape. For example,sections of the outline are regarded as essentially linear when they areat least partly or even entirely curved and have a radius of curvatureof at least twice, preferably at least five times, more preferably atleast ten times, the diameter of the abrasive grain. The same applies toshell segments, which may likewise have a slight curvature. A point onthe outline is regarded essentially as a corner when the radius ofcurvature there is not more than 10%, preferably not more than 5%, morepreferably not more than 2%, of the diameter of the abrasive grain. Inaddition, the two base faces are also understood to be essentially flatwhen they have concave or convex curvature and have radii of curvaturewhich are at least twice, preferably at least five times, morepreferably at least ten times, the diameter of the abrasive grain. Thebase faces may also each contain a plurality of essentially mutuallyparallel face sections which are in contact with one another at one ormore edges and/or corners. “Essentially parallel” means that the anglebetween the face sections is less than 20°, preferably less than 10° andmore preferably less than 5°. Curves, edges or corners in the base facesmay, for example, as a result of production, arise from the upper freesurface of the dispersion which is not in contact with a die. Inaddition, the base faces are also regarded as essentially parallel toone another when they are arranged at an angle to one another that is atmost 10°, preferably at most 5°, more preferably at most 2°.

The abovementioned tolerances apply independently of one another. Forexample, it is conceivable that the base faces are flat and the shellsegments have slight curvature. Conversely, it is also conceivable thatthe base faces have slight curvature, while the shell segments arestraight. Preferably, however, the abrasive grain has an idealized shapeas described above in relation to every inventive geometric property.

The abrasive grain may, for example, comprise or consist of a ceramicmaterial, especially a polycrystalline ceramic material. Preferably, theabrasive grain comprises alumina, more preferably α-Al2O3.

Alternatively or additionally, the abrasive grain may also comprise atleast one further metal oxide, for instance sodium oxide, magnesiumoxide, iron oxide, silicon oxide, calcium oxide, zirconium oxide,yttrium oxide, zinc oxide, cobalt oxide, nickel oxide, hafnium oxide,chromium oxide, praseodymium oxide, samarium oxide, ytterbium oxide,neodymium oxide, lanthanum oxide, gadolinium oxide, cerium oxide,dysprosium oxide, erbium oxide, lutetium oxide, titanium oxide,manganese oxide or any desired combinations thereof.

Many of these metal oxides originate from impurities in the startingmaterials, for example in alumina. Given sufficiently low proportions inthe abrasive grain, however, such impurities have no adverse effect onthe production and use of the abrasive grain. Some of these impuritiesmay even have a positive effect on the abrasive grain.

Fractions of zirconium oxide or yttrium oxide may originate, forexample, from grinding balls which can be used in a grinding step in theproduction of the abrasive grains. Fractions of iron oxide may originatefrom a grinding vessel which is used in such a grinding step.

Likewise alternatively or additionally, the abrasive grain may comprisefurther hard substances, for example silicon carbide.

In addition, the abrasive grain may comprise at least one breakdownproduct of a dispersant described in detail hereinafter, which was usedin the production of the abrasive grains. In addition, the abrasivegrain may comprise at least one nucleating agent or breakdown productthereof which was used in the production of the abrasive grains. Thenucleating agent may, for example, be magnesium oxide which has alreadybeen mentioned above.

Moreover, the abrasive grain may also comprise at least one of thefurther substances described in EP 615 816 A1.

The ingredients mentioned can be determined with the aid of chemicalanalysis methods known per se.

The abrasive grain may comprise or consist of a structure having one ormore different phases. A first phase may consist of alumina, morepreferably of α-Al₂O₃. A second phase may consist of one or more of theabovementioned further metal oxides and/or further hard substances.

The proportion of alumina, especially of α-Al2O3, in the abrasive grainmay, for example, be at least 25% by weight, preferably at least 50% byweight, further preferably at least 70% by weight, more preferably atleast 95% by weight.

The abrasive grain may have a coating which covers only part of thesurface, especially only one or more edges and/or only one of severalflat areas of the surface. The coating may, for instance, be aferromagnetic or paramagnetic coating. Such a partial coating of thesurface with a ferromagnetic or paramagnetic material enables alignmentof the abrasive grain in a given direction in a magnetic field appliedduring the scattering operation. Alternatively, it may also be a coatingof a material having elevated thermal conductivity or a coating whichenables increased adhesion of the abrasive grain on the abrasiveunderlayer.

A further aspect of the invention relates to a collective of abrasivegrains. A collective of abrasive grains is understood here andhereinafter to mean a coherent collection of abrasive grains. Forexample, this may be a collection of abrasive grains which are presentin a container and are stored and transported as such, for example in asack.

Such a collection of abrasive grains can also be used to produce anabrasive article. A collective of abrasive grains is also regarded asthe entirety of all the abrasive grains present in an abrasive article.

Preferably, the collective of abrasive grains contains at least 20% byweight, preferably at least 50% by weight and more preferably at least90% by weight of inventive abrasive grains as described above. The otherabrasive grains present in the collective may likewise have a definedshape, but one which differs from the inventive shape, or they may nothave a defined shape since they are, for example, broken abrasivegrains. These other abrasive grains present in the collective are alsoreferred to as “support grains”.

It is conceivable and likewise within the scope of the invention thatthe inventive abrasive grains present in the collective are differentfrom one another. For example, the collective of abrasive grains maycontain a first fraction of abrasive grains of a first embodiment of theinvention, and a second fraction of abrasive grains of a secondembodiment of the invention that are different from the first embodimentof the invention. More particularly, the abrasive grains of the firstembodiment of the invention may differ in terms of size and shape fromthe abrasive grains of the second embodiment of the invention.

The collective of abrasive grains may consist exclusively of identicalinventive abrasive grains; more particularly, the collective in thatcase has a size distribution in the form of points.

The collective of abrasive grains may essentially have a sizedistribution which corresponds to a size standard customary in theabrasives industry, for example the American National StandardsInstitute (ANSI), the Standards of the Federation of European Producersof Abrasives (FEPA) or the Japanese Industrial Standard (JIS). Forexample, the collective of the abrasive grains may essentially have agrain size of P12, P16, P20, P24, P30, P36, P40, P50, P60, P80, P100,P120, P150, P180, P220, P240, P280, P320, P360, P400, P500, P600, P800,P1000, P1200, P1500, P2000, P2500, P3000 or P5000 according to the FEPAstandard. In this context, a size distribution “essentially” means thatat least 90% by weight, preferably at least 95% by weight, furtherpreferably at least 99% by weight and more preferably all of theabrasive grains in the collective of abrasive grains meet this standard.

As already described above, it is also conceivable that the collectivecontains at least two different fractions of inventive abrasive grainsand/or at least one fraction of noninventive abrasive grains. Each ofthese fractions may itself have a size distribution corresponding ineach case to one of the abovementioned size standards customary in theabrasives industry.

An inventive abrasive grain or an inventive collective of abrasivegrains can be produced, for example, by the following process known fromU.S. Pat. No. 5,201,916:

-   -   a. producing or providing a dispersion comprising α-alumina        particles and/or particles that can be converted to α-alumina,        and at least one volatile dispersion medium, preferably water;    -   b. introducing the dispersion into at least one depression of a        die;    -   c. optionally squeegeeing an upper face of the die in order to        remove at least a portion of the dispersion which stands above        the upper face of the die;    -   d. removing a portion of the volatile components of the        dispersion, so as to form at least one abrasive grain precursor;    -   e. removing the abrasive grain precursor from the die;    -   f. optionally calcining the abrasive grain precursor;    -   g. sintering the abrasive grain precursor in order to obtain at        least one abrasive grain.

Before and/or during the production of the dispersion in step a), theraw materials, especially α-alumina particles and/or particles that canbe converted to α-alumina, are ground. This can be effected, forexample, with the aid of a ball mill, especially with the aid of aplanetary ball mill.

The dispersion may comprise at least one dispersant. Such a dispersantfacilitates the formation of the dispersion and increases the stabilitythereof by, for example, forming layers around the individual grainswhich prevent lump formation. The dispersant may, for example, be apolymer. In general, the dispersant breaks down during the sintering instep g) if not earlier.

The die may comprise or consist of silicone, for example. Thedepressions may have an open top face through which the dispersion canbe introduced. The depressions in the die each have a surface whoseshape is complementary to the shape of at least one portion of thesurface of the desired abrasive grain. For this purpose, the surface ofthe depression may have a base face which is of the same shape as thebase face of the abrasive grains to be produced and runs parallel to thetop side of the die. A lateral wall extends from the base face, beingformed by an array of parallel segments and being complementary to theshell face of the abrasive grains to be produced. More particularly, thelateral wall thus has at least one convex section.

The precursor that forms in step d) should preferably be of sufficientmechanical stability to be further processible as bulk material in thesubsequent steps. The optional calcining in step f) is advantageous oreven required especially when the dispersion comprises a plurality ofdifferent raw materials and a phase transformation is required.

Another aspect of the invention relates to an abrasive articlecontaining a collective of abrasive grains as described above. Moreparticularly, it is thus possible for at least 20% by weight, preferablyat least 50% by weight, more preferably at least 90% by weight, of allthe abrasive grains of the abrasive article to take the form ofinventive abrasive grains as described above. The other abrasive grainsmay likewise have a defined shape, but one which differs from theinventive shape, or they may not have a defined shape.

The abrasive article may, for example, be a coated abrasive article, anabrasive article web, a bonded abrasive article or an abrasive brush.

A coated abrasive article comprises an underlayer, especially a flexibleunderlayer, for example paper, vulcanized fiber, a film, a textilematerial, a foam or multilayer combinations thereof. The abrasive grainscan be secured to the underlayer with the aid of a base binder (“makecoat”). The make coat and the abrasive grains may be covered with a topbinder (“size coat”). Optionally, above the size coat mentioned, it isalso possible for a second top binder (“supersize coat”) to be present.

The make coat, size coat and supersize coat used may be any bindersknown per se, for example composed of synthetic resin, for instance aphenolic resin, an epoxide, a urea resin, a melamine resin or anunsaturated polyester resin. The size coat and/or supersize coat mayadditionally comprise further customary active ingredients and/orfillers.

The abrasive article may be in different product forms, for example asan abrasive disk or as an abrasive belt.

The invention also encompasses a process for producing an inventiveabrasive article as described above. The process comprises a step inwhich a collective of abrasive grains is fixed on and/or in a substrate,especially by means of a binder. The substrate may, for instance, be anunderlayer, especially a flexible underlayer, of a coated abrasivearticle, a web material for an abrasive web, a matrix for a bondedabrasive or bristle for an abrasive brush. In the case of a coatedabrasive article, the make coat and/or the abrasive grains and/or thesize coat and/or supersize coat can be applied by a method known per se.For example, the abrasive grains can be applied by electrostatic ormechanical means (i.e. by gravimetric means). Electrostatic scatteringis preferred especially when the ratio of height and diameter of theabrasive grain is comparatively small.

This is because, in the case of mechanical scattering, such abrasivegrains would be more likely to be aligned in such a way that their basefaces lie parallel on the surface. The above-described advantages of theinventive shape of the abrasive grains would thus be reduced at least inpart. In contrast, the greater said ratio is, the fewer abrasive grainsare aligned such that their base faces lie parallel on the surface, andthe more reliable mechanical scattering is.

In addition, the invention is also directed to a process for grinding asurface with an abrasive article as described above. The surface mayespecially be a painted surface. In the case of a painted surface,abrasive grains having sizes of 500 μm or less are particularlysuitable.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated hereinafter with reference to severalworking examples and drawings. These show:

FIG. 1A: a perspective view of a first embodiment of an inventiveabrasive grain;

FIG. 1B: a front view of the abrasive grain from FIG. 1A;

FIG. 1C: a side view of the abrasive grain from FIG. 1A;

FIG. 1D: a top view of the abrasive grain from FIG. 1A;

FIG. 1E: a side view of the abrasive grain from FIG. 1A aligned on anunderlayer;

FIG. 2A: a perspective view of a modified abrasive grain from FIG. 1A;

FIG. 2B: a side view of the abrasive grain from FIG. 2A;

FIG. 2C: a section through the abrasive grain from FIG. 2A along a planethrough two opposite corners;

FIG. 2D: a side view of the abrasive grain from FIG. 2A aligned on anunderlayer;

FIG. 3A: a perspective view of a further embodiment of an inventiveabrasive grain;

FIG. 3B: a top view of the abrasive grain from FIG. 3A;

FIG. 3C: a front view of the abrasive grain from FIG. 3A;

FIG. 4: a perspective view of a further embodiment of an inventiveabrasive grain;

FIG. 5: a perspective view of a further embodiment of an inventiveabrasive grain;

FIG. 6: a further embodiment of an inventive abrasive grain in aperspective view;

FIG. 7: a further embodiment of an inventive abrasive grain in aperspective view;

FIG. 8: a further embodiment of an inventive abrasive grain in aperspective view;

FIG. 9: a further embodiment of an inventive abrasive grain in aperspective view;

FIG. 10: a schematic lateral section view of an extruder for productionof abrasive grains;

FIG. 11A: a top view of the extruder according to FIG. 10 having a firstnozzle;

FIG. 11B: a top view of an extruder according to FIG. 10 having a secondnozzle;

FIG. 11C: a top view of an extruder according to FIG. 10 having a thirdnozzle;

FIG. 11D: a top view of an extruder according to FIG. 10 having a fourthnozzle;

FIG. 11E: a top view of an extruder according to FIG. 10 having a fifthnozzle;

FIG. 12A: an abrasive grain produced with the first nozzle according toFIG. 11A;

FIG. 12B: an abrasive grain produced with the second nozzle according toFIG. 12B;

FIG. 13: an abrasive grain with the shape of a twisted cuboid;

FIG. 14A: a further embodiment of an inventive abrasive grain inperspective view;

FIG. 14B: a schematic section diagram of the embodiment according toFIG. 14A of the inventive abrasive grain;

FIG. 15A: a further embodiment of an inventive abrasive grain inperspective view;

FIG. 15B: a schematic side view of the embodiment according to FIG. 15Aof the inventive abrasive grain;

FIG. 15C: a further schematic side view of the embodiment according toFIG. 15A of the inventive abrasive grain;

FIG. 15D: a schematic top view of the embodiment according to FIG. 15Aof the inventive abrasive grain;

FIG. 16A: a further embodiment of an inventive abrasive grain;

FIG. 16B: a schematic section diagram of the embodiment according toFIG. 16A;

FIG. 17: a further embodiment of an inventive abrasive grain;

FIG. 18: a further embodiment of an inventive abrasive grain;

FIG. 19: a further embodiment of an inventive abrasive grain;

FIG. 20A: a further embodiment of an inventive abrasive grain inperspective view;

FIG. 20B: a schematic section diagram of the embodiment according toFIG. 20A of the inventive abrasive grain;

FIG. 21: a further embodiment of an inventive abrasive grain;

FIG. 22: a further embodiment of an inventive abrasive grain;

FIG. 23: a further embodiment of an inventive abrasive grain;

FIG. 24: a side view of a known abrasive grain in the processing of asurface;

FIG. 25A: a first view of a further embodiment of an inventive abrasivegrain;

FIG. 25B: a second view of the abrasive grain of FIG. 25A;

FIG. 26: a side view of a further embodiment of an inventive abrasivegrain;

FIG. 27: a side view of a further embodiment of an inventive abrasivegrain;

FIG. 28: a side view of a further embodiment of an inventive abrasivegrain;

FIG. 29A: a first view of a further embodiment of an inventive abrasivegrain;

FIG. 29B: a second view of the abrasive grain of FIG. 29A;

FIG. 30A: a first view of a further embodiment of an inventive abrasivegrain;

FIG. 30B: a second view of the abrasive grain of FIG. 30A;

FIG. 31: a die for production of an abrasive grain of the inventiveembodiment according to FIG. 28.

DETAILED DESCRIPTION

FIGS. 1A to 1E show an inventive abrasive grain 10 in a firstembodiment. FIG. 1A shows a perspective view, FIG. 1B shows a frontview, FIG. 1C shows a side view, and FIG. 1D shows a top view. FIG. 1Eshows the abrasive grain 10 in a side view, the abrasive grain 10 beingdisposed on an underlayer 20. The abrasive grain 10 has a virtuallysquare outline with four corners 1 to 4 and four edges 4 to 8 that jointhe corners 1 to 4. The edges 5 to 8 are straight, although curved edgesare also conceivable. Proceeding from a flat square, however, twomutually opposite corners 2, 4 are shifted upward out of the plane, andthe two other mutually opposite corners 1, 3 are shifted downward out ofthe plane. The abrasive grain 10 therefore has only two faces 11, 12.These two faces 11, 12 in the working example shown are identical, i.e.form merely the top side and bottom side of a single face.Alternatively, it is also conceivable that both faces have a differentcurvature profile and therefore enclose a volume between the two faces11, 12.

As is apparent in FIG. 1E, the abrasive grain 10 lines up on anunderlayer 20 such that three corners 1 to 3 lie on the underlayer 20,while the remaining corner 4 protrudes from the underlayer 20. The planeformed from the three corners 1, 3 and 4 is at an angle a from theunderlayer 20. This angle a is simultaneously the angle between the twoplanes formed by the corners 1, 3 and 4 or 1, 2 and 3. In the embodimentshown, the angle a is obtuse.

FIGS. 2A to 2D show the abrasive grain 10 from FIG. 1A in slightlymodified form. FIG. 2A shows a perspective view, FIG. 2B a side view,FIG. 2C a section through the abrasive grain 10 from FIG. 2A along aplane through two opposite corners 1, 3, and FIG. 2D another side view,with the abrasive grain 10 aligned on an underlayer 20. The respectivelyopposite corners 1, 3 and 2, 4 are respectively shifted further upwardand downward out of the plane with respect to FIG. 1A. As shown in FIG.2D, a smaller angle a is correspondingly formed between the underlayer20 and the plane formed from the corners 1, 2 and 3. The angle a isacute. According to the configuration of the angle a, the abrasioncharacteristics of the abrasive grain 10 can be significantlyinfluenced. In the section in FIG. 2C, it is clearly apparent that thetwo faces 11, 12 of the abrasive grain 10 enclose a volume.

FIGS. 3A to 3C show a further embodiment of an inventive abrasive grain10. FIG. 3A shows a perspective view, FIG. 3B a top view and FIG. 3C afront view of the abrasive grain 10. This abrasive grain 10 has twomutually skewed edges 5, 7, the respective ends of which are bounded bya corner 1, 2 and 3, 4 respectively. The abrasive grain 10 has fourcorners 1 to 4. The two edges 5, 7 are arranged at an angle of 90°relative to one another. The abrasive grain 10 has a single face 11which takes the form of a continuous curved face. For easierunderstanding of the shape, it is possible to imagine a cylindricalpiece of tube which is closed off and flattened at either end, the twoclosures being arranged at right angles to one another and the abrasivegrain 10 being formed by the cavity surrounded by the closed-off pieceof tube. In FIGS. 3A and 3C, the common perpendicular is drawn in forschematic purposes, which simultaneously defines the distance D betweenthe skewed edges 5, 7. The length of the edges 5, 7 is the same as thedistance D. Typically, the ratio of the edge length to the distance D isbetween 0.5 and 2.0, preferably between 0.7 and 1.4, more preferablybetween 0.9 and 1.1. In the embodiment shown, the edges 5, 7 arearranged such that the common perpendicular in each case is in themiddle of the edges 5, 7. Also conceivable, of course, are abrasivegrains in which the common perpendicular has been shifted from themiddle. There is also no need for the edges 5, 7, as shown in theworking example, to run straight; curved edges are also entirelyconceivable.

FIGS. 4 and 5 show, in perspective view, two further embodiments of aninventive abrasive grain 10. These abrasive grains 10 again have fourcorners 1 to 4. The corners 1 to 4 are each joined to one another viathe edges 5 to 6, similarly to FIG. 1A. In addition, however, twomutually opposite corners 1, 3 are joined by a further edge 9. The edges5 to 9 are all curved lines, but it is also conceivable that the edgesare straight. Curved faces 11, 12 are formed between the corners 1, 2and 3 or 1, 3 and 4, these being concave. Flat faces are alsoconceivable. A primary face 13 is formed between all four corners 1 to4, this again being curved. A vertex line 14 of the primary face 13 isconcave in the embodiment according to FIG. 4, whereas the vertex line14 is convex in FIG. 5. However, the vertex line 14 does not itself forman edge of the abrasive grain. The two embodiments according to FIGS. 4and 5 also differ by an angle α which is formed between the planesformed from the corners 1, 2 and 3 or 1, 3 and 4. In FIG. 4 this angle ais 90°; in FIG. 5 the angle α is 135°. It will be apparent that theseangles α may each also have other values. The two abrasive grains 10according to FIGS. 4 and 5 are also symmetric with respect to a plane atright angles to a straight line connecting the corners 1 and 3 or 2 and4. Such a symmetry facilitates the production of corresponding dies. Inaddition, the abrasive grains 10 according to FIGS. 4 and 5 may lie in afirst orientation on corners 1, 3 and 4 on an abrasive underlayer, or ina second orientation on corners 1, 2 and 3. In both orientations, thecorners 2 or 4 pointing away from the underlayer in each case aresimilar to one another because of the symmetry; the abrasive action isthus independent of which of the two orientations is present. Moreover,the abrasive grains 10 in FIGS. 4 and 5 are symmetric about an axis ofsymmetry which runs at the midpoint between the two corners 1 and 3 andintersects the edge 9.

The inventive abrasive grains can be produced, for example, by a processdescribed hereinafter: first of all, a dispersion of 200 g of α-Al₂O₃,0.4 g of MgO, 90 g of water as dispersion medium and 0.5 g of dispersantis produced. The MgO functions here as a nucleating agent. Thedispersant used may, for example, be the Dolapix CE64 product obtainablefrom Zschimmer & Schwarz, 56108 Lahnstein, Germany. The dispersion thusobtained is ground in a planetary ball mill at 200 revolutions perminute for 30 minutes, for example a PM400 planetary ball millobtainable from Retsch GmbH, 42781 Haan, Germany. Subsequently, theground dispersion is introduced into a silicone die containingdepressions in the shape of the desired abrasive grains. For someembodiments of the abrasive grain, it is possible to use an additionalshaping element as described above, for example a further die, withwhich, in addition to the surface shaped in the die, it is possible toshape at least a portion of the rest of the surface of the abrasivegrain. Thereafter, the volatile component, i.e. the water, is removedfrom the dispersion. This gives rise to an abrasive grain precursorwhich is removed from the die. In a final step, the precursor issintered as bulk material at 1550° C. for 5 minutes. The dispersant isburnt out in the course of sintering.

An inventive abrasive article can be produced, for example, as follows:on an underlayer made from vulcanized fiber having a thickness of 0.8mm, a phenol resin dispersion as make coat precursor is applied in anamount of 120 g/m². Subsequently, 600 g/m² of the inventive abrasivegrains are applied by means of electrostatic scattering. Thereafter, themake coat precursor is cured to give a make coat. On top of the makecoat and the abrasive grains, a phenol resin dispersion is applied in anamount of 800 g/m² as size coat precursor, which is likewise cured.

FIG. 6 shows, in perspective view, a first embodiment of an inventiveabrasive grain 110. The abrasive grain 110 contains a base element 120and a top element 125. The base element 120 contains a bottom side 121and a parallel opposite top side 122, on which is disposed a bottom side126 of the top element 125. Both the base element 120 and the topelement 125 have the shape of a twisted cuboid, i.e. of a specifictwisted straight prism. The base element 120 and the top element 125 aretwisted with respect to the theoretical cuboids about a common twistaxis V which runs at right angles to the bottom side 121 and to the topside 122 of the base element 120 and at right angles to the bottom side126 and to a top side 127 of the top element 125.

The angle by which the cross sections of the base element 120 which runat right angles to the twist axis V have been rotated compared to thetheoretical cuboid has a linear dependence on the distance of thesectional plane from the bottom side 121 of the base element 120.Likewise, the angle by which the cross sections of the top element 125which run at right angles to the twist axis V have been rotated comparedto the theoretical cuboid has a linear dependence on the distance of thesectional plane from the bottom side 126 of the top element 125. Bothfor the base element 120 and for the top element 125, the angledifferential between the respective bottom side 121 or 126 and therespective top side 122 or 127 here is 90°. In a departure from theworking example shown here, this angle for the base element 120 may alsobe about 45°, because corners of the underside 121 of the base element120 then project beneath the top side 122 of the base element 120 as aresult, which can assure particularly good anchoring in a make coat.

The effect of the twisting of the base element 120 is that the baseelement 120 can be anchored better in a make coat of an abrasive articlenot shown here. The result of the twisting of the top element 125 isthat swarf formed in the course of grinding can be transported away froma surface being processed.

In the second embodiment shown in FIG. 7, the abrasive grain 210contains an untwisted base element 220 in the form of an untwistedfrustopyramid and a top element 225 in the form of a twisted pyramid.

The abrasive grain 310 according to FIG. 8 consists of only a singletwisted component 320; it is thus not composed of a base element and atop element like the abrasive grains 110 and 210. The component 320 hasthe shape of a twisted cylinder with an elliptical base face 321 and anelliptical top face 322.

The abrasive grain 410 shown in FIG. 9 likewise consists only of asingle twisted component 420 which has the shape of a twistedpolyhedron. The theoretical polyhedron has the shape of a prism with twotriangular end faces 421, only one of which can be seen here, and threerectangular lateral faces 422, 422′ and 422″. The component 420 istwisted with respect to the theoretical polyhedron about a twist axis Vwhich runs at right angles to the center of the lateral face 422.

The inventive abrasive grains can be produced, for example, by a processdescribed hereinafter: first of all, a dispersion of 200 g of α-Al₂O₃,0.4 g of MgO, 90 g of water as dispersion medium and 0.5 g of dispersantis produced. The MgO functions here as a sintering aid, in order tosuppress grain growth. The dispersant used may, for example, be theDolapix CE64 product obtainable from Zschimmer & Schwarz, 56108Lahnstein, Germany. The dispersion thus obtained is ground in aplanetary ball mill at 200 revolutions per minute for 30 minutes, forexample a PM400 planetary ball mill obtainable from Retsch GmbH, 42781Haan, Germany. Subsequently, the ground dispersion is introduced into asilicone die containing depressions in the shape of the desired abrasivegrains. Thereafter, the volatile component, i.e. the water, is removedfrom the dispersion. This gives rise to an abrasive grain precursorwhich is removed from the die. If the abrasive grain contains a baseelement as described above with a bottom side, this bottom side can formfrom the upper free surface of the dispersion which is not in contactwith the die. In a final step, the precursor is sintered as bulkmaterial at 1550° C. for 5 minutes. The dispersant is burnt out in thecourse of sintering.

FIG. 10 shows, in a schematic lateral section view, an extruder 500 forproduction of inventive abrasive grains. The extruder 500 contains ahollow cylinder 501 with a screw 502 arranged therein. The screw 502 canbe driven in a rotating manner with the aid of a motor 503. By means ofan introduction funnel 504, a dispersion is introduced into the interiorof the hollow cylinder 501. This dispersion contains α-alumina particlesand/or particles that can be converted to α-alumina, and at least onevolatile dispersion medium, preferably water, and preferably at leastone organic additive, for example the plasticizer Zusoplast C21,available from Zschimmer & Schwarz, 56108 Lahnstein, Germany. With theaid of the screw 502, the dispersion is conveyed to a constricted exitend 505 and forced through an exit orifice of a nozzle 506, 506′, so asto form an extrudate which is not shown here. The exit orifice has theshape of a twisted cylinder. With the aid of rotating blades which arelikewise not shown here, the extrudate is severed to form individualabrasive grain precursors which can subsequently be calcined and thensintered.

FIGS. 11A to 11E show top views of five nozzles 506, 506′, 506″, 506′″,506′′″. These nozzles 506, 506′, 506″, 506′″, 506′′″ each have exitorifices 507, 507′, 507″, 507′″ and 507′′″ respectively. The exitorifice 507 has the shape of an equilateral triangle, the exit orifice507′ the shape of a square, the exit orifice 507″ the shape of arectangle with rounded corners, the exit orifice 507′″ the shape of anellipse, and the exit orifice 507′′″ the shape of a lens. FIGS. 11C to11E show the length 1 and the width b of the exit orifice.

The extrudate obtained with the nozzle 506 according to FIG. 11A has theshape of a twisted prism having a base face of an equilateral trianglewith side length a. With the aid of the rotating blades, individualabrasive grain precursors are obtained, which, after calcining andsintering, give rise to abrasive grains 510, one of which is reproducedin FIG. 12A. This abrasive grain 510 has a base face 521 and a top face522 and has a height h measured along the twist axis V, where the ratioof side length a to height h may be in the range from 1:3 to 8:1,preferably from 1:1 to 7:1 and more preferably from 4:1 to 6:1. In theabrasive grain 510 shown in FIG. 12A, the overall twist angle (i.e. theangle differential between the base face 521 and the top face 522) is60°. Even more preferred than the abrasive grain 510 shown in FIG. 12Aare abrasive grains in the shape of a twisted prism having base face andtop face in the shape of equilateral triangles when the overall twistangle is in the range from 5° to 30° and is most preferably about 10°.

An abrasive grain 510′ which has been obtained with the nozzle 506′according to FIG. 11B and which has the shape of a twisted cuboid withside length a′ is shown in FIG. 12B. This abrasive grain 510′ has aheight h′ measured along a twist axis V′, where the ratio of side lengtha′ to height h′ may be in the range from 1:3 to 8:1, preferably from 1:1to 7:1 and more preferably from 4:1 to 6:1. In this abrasive grain 510′,the overall twist angle between base face 521′ and top face 522′ is 90°,which is particularly preferred for abrasive grains in the shape oftwisted cuboids having rectangular, especially square, base and topfaces.

An inventive abrasive article can be produced, for example, as follows:on an underlayer made from vulcanized fiber having a thickness of 0.8mm, a phenol resin dispersion as make coat precursor is applied in anamount of 120 g/m². Subsequently, 600 g/m² of the inventive abrasivegrains are applied by means of electrostatic scattering. Thereafter, themake coat precursor is cured to give a make coat. On top of the makecoat and the abrasive grains, a phenol resin dispersion is applied in anamount of 800 g/m² as size coat precursor, which is likewise cured.

The abrasive grain 810 shown in FIG. 13 has the shape of a twistedcuboid. The base face 821 and the top face 822 each have a length a anda width b, the ratio of which is preferably in the range from 10:2 to10:3. In addition, the abrasive grain 810 has a height h measured alongthe twist axis V, which is preferably in a ratio to the length a of 4:1to 6:1. The overall twist angle of this abrasive grain 810 is 90°.

FIG. 14A shows a first embodiment of an inventive abrasive grain 100 inperspective view. The abrasive grain has a structure having six faces110 having concave curvature 111.

The concave curvature 111 becomes clear in FIG. 14B, which shows aschematic section diagram of the first embodiment of the inventiveabrasive grain 100. The convex corners 112 of the structure correspondto the corners of an imaginary cube.

The faces 110 are curved in two spatial directions 114, 115.

The edges 113 likewise have concave curvature.

The edges 113 which run toward the corners 112 form, by virtue of theface 110 pulled inward, more acute angles at the corners 112 than theedges of a cube.

The base face of the cube has high symmetry, and so the face on whichthe abrasive grain 100 comes to rest when scattered is immaterial. Thisis particularly advantageous in the case of mechanical scattering, withwhich the abrasive grains, in contrast to electrostatic scattering,cannot be aligned with the aid of an electrical field.

FIG. 15A shows a second embodiment of an inventive abrasive grain 200 inperspective view. The abrasive grain 200 has a structure with threereentrant corners 216, which becomes particularly clear in FIG. 15D,which shows a schematic top view of the second embodiment of theinventive abrasive grain 200.

The convex corners 212 of the structure correspond to the corners of animaginary tetrahedron, i.e. of a Platonic solid.

The reentrant corner 216 is shifted inward compared to the tetrahedralface. There is therefore a tangential plane, i.e. a plane which includesthe reentrant corner 216, on which a circle with the corner 216 as thecenter can be defined, the circumference of which is entirely within thesolid.

The effect of the corners 216 pulled inward is that the faces 210 meetat the edges 213 at a more acute angle than in a tetrahedron. Theabrasive grain 200 therefore has sharp edges and good cutting power.

FIG. 15B and 15C show schematic side views of the second embodiment ofthe inventive abrasive grain 200.

There is no reentrant corner on the base face of the abrasive grain,which is not shown explicitly. The base face therefore contains morematerial. When scattered, the abrasive grain 200 will come to restpreferentially on the heavier side, i.e. the base face. Ideally, thebase face is flat. However, it is possible and covered by the inventionthat the base face, as a result of production, has slight concavecurvature which can arise because of the above-described shrinkageduring the removal of the volatile components.

FIG. 16A shows a third embodiment of an inventive abrasive grain 300 inperspective view. The abrasive grain 300 has a structure with reentrantcorners 316, which becomes particularly clear in FIG. 16B, which shows aschematic section view of the third embodiment of the inventive abrasivegrain 300.

The convex corners 312 of the structure correspond to the corners of animaginary cube, i.e. of a Platonic solid.

The edges 317 that run toward the convex corners 312 are curved.

The faces 310 of the abrasive grain 300 that meet at the edges 317 forma more acute angle than in the case of a cube.

FIG. 17 shows a fourth embodiment of an inventive abrasive grain 400 inperspective view. The convex corners 412 correspond to the corners of animaginary frustotetrahedron, i.e. of an Archimedean solid. The faces 410have concave curvature.

FIG. 18 shows a fifth embodiment of an inventive abrasive grain 500 inperspective view. The convex corners 512 correspond to the corners of animaginary tetrahedron. Three tetrahedral edges are capped in such a wayas to give rise to faces 510 with concave curvature.

FIG. 19 shows a sixth embodiment of an inventive abrasive grain 600 inperspective view. The convex corners 612 correspond to the corners of animaginary frustotetrahedron, i.e. of an Archimedean solid. The edges arecapped in such a way that I give rise to faces 610 with concavecurvature.

FIG. 20A shows a seventh embodiment of an inventive abrasive grain 700in perspective view. The convex corners of the solid correspond to thecorners of an imaginary tetrakis hexahedron, i.e. of a Catalan solid.

The concave curvature 711 of the faces 710 becomes clear in FIG. 20B,which shows a schematic section view of the seventh embodiment of theinventive abrasive grain 700.

The edges 713 likewise have concave curvature.

The edges 713 that run toward the corners 712, by virtue of the face 710pulled inward, form more acute angles at the corners 712 than the edgesof a tetrakis hexahedron.

FIG. 21 shows an eighth embodiment of an inventive abrasive grain 800 inperspective view. The convex corners 812 correspond to the corners of animaginary prism. The faces 810 have concave curvature, and so the faces810 at the edges 813 form more acute angles than in a prism.

FIG. 22 shows a ninth embodiment of an inventive abrasive grain 900 inperspective view. The convex corners 912 correspond to the corners of animaginary prism. The faces 910 have concave curvature, and so the faces910 at the edges 913 form more acute angles than in an antiprism.

FIG. 23 shows a tenth embodiment of an inventive abrasive grain 1000 inperspective view. The abrasive grain 1000 has a structure with faces1010 having concave curvature. At the edge of the curved faces, sharpedges 1013 are formed.

The inventive abrasive grains can be produced, for example, by a processdescribed hereinafter: first of all, a dispersion of 200 g of α-Al₂O₃,0.4 g of MgO, 90 g of water as dispersion medium and 0.5 g of dispersantis produced. The MgO functions here as a nucleating agent. Thedispersant used may, for example, be the Dolapix CE64 product obtainablefrom Zschimmer & Schwarz, 56108 Lahnstein, Germany. The dispersion thusobtained is ground in a planetary ball mill at 200 revolutions perminute for 30 minutes, for example a PM400 planetary ball millobtainable from Retsch GmbH, 42781 Haan, Germany. Subsequently, theground dispersion is introduced into a silicone die containingdepressions in the shape of the desired abrasive grains. For someembodiments of the abrasive grain, it is possible to use an additionalshaping element as described above, for example a further die, withwhich, in addition to the surface shaped in the die, it is possible toshape at least a portion of the rest of the surface of the abrasivegrain. Thereafter, the volatile component, i.e. the water, is removedfrom the dispersion. This gives rise to an abrasive grain precursorwhich is removed from the die. In a final step, the precursor issintered as bulk material at 1550° C. for 5 minutes. The dispersant isburnt out in the course of sintering.

An inventive abrasive article can be produced, for example, as follows:on an underlayer made from vulcanized fiber having a thickness of 0.8mm, a phenol resin dispersion as make coat precursor is applied in anamount of 120 g/m². Subsequently, 600 g/m² of the inventive abrasivegrains are applied by means of electrostatic scattering. Thereafter, themake coat precursor is cured to give a make coat. On top of the makecoat and the abrasive grains, a phenol resin dispersion is applied in anamount of 800 g/m² as size coat precursor, which is likewise cured.

FIG. 24 shows, in schematic form, the processing of a surface 50 with anabrasive article 40 having a known abrasive grain 10. For simplificationof the diagram, only a single abrasive grain 10 is shown here, eventhough the abrasive article 40 of course does in fact contain amultitude of such abrasive grains 10. The abrasive grain 10 has beenfixed on a substrate 41 with the aid of a binder 42. It has the shape ofa straight cylinder having a base face 11 in the shape of an equilateraltriangle. A flat section of the abrasive grain 10 which is in contactwith a linear section 14 of the outline 12 lies against the underlayer41, such that a tip 17 of the abrasive grain 10 is directed toward thesurface 50. Between a cutting face 16 and a perpendicular S to thesurface 50, an angle of engagement δ of +30° is formed. This is given apositive sign here, since the perpendicular S runs within the abrasivegrain 10. Such an angle of engagement leads only to a comparativelyminor cutting effect.

FIGS. 25A and 25B show a first inventive abrasive grain 10. According tothe perspective view in FIG. 25A, the abrasive grain 10 has the shape ofa cylinder having two opposite base faces 11, only one of which can beseen here. A shell face 18 extends between the two base faces 11. Thecylinder has a height h.

FIG. 25B shows a top view of one of the base faces 11. The abrasivegrain 10 has a diameter corresponding to the diameter of a circleenveloping the base face 11 which is not shown here. The outline 12 hasthree concave section 13. The concave sections 13 are each formed by twolinear component sections 19 which converge at a reflex corner 20. Allcomponent section 19 have the same length, and all reflex corners 20have the same angle. The concave section 13 end at corners 15. Since thelines connecting two adjacent corners 15 run outside the base face 11,the section 13 that run in between are referred to as concave in thecontext of the invention. In addition, straight sections 14 extendbetween adjacent corners 15, which likewise have the same length as oneanother. The internal angle a at each corners 15 may, for example, be105° (this does not correspond to the angle shown in the merelyschematic drawing).

FIG. 25B also shows an imaginary support plane E of the abrasive grain10. The linear section 14 shown at the top of FIG. 25B runs parallel tothis support plane E, i.e. at an angle of 0° to the support plane E. Ifthe abrasive grain 10 lies on an abrasive underlayer 41 such that thesupport plane E corresponds to the underlayer 41, the abrasive grain 10is stable to tipping over. In this orientation, the linear section 14shown at the top runs parallel a surface 50 being processed, and thepart-sections 19 of the concave sections 13 form cutting faces.

For the abrasive grain 10 shown in FIGS. 25A and 25B, an angle ofengagement of δ=α−90°=15° is found. In the working example shown here,this angle of engagement δ corresponds to the angle formed between thepart-section 19 and a perpendicular S which runs at right angles to thesupport plane E. The angle of engagement δ of this inventive abrasivegrain 10 is smaller than the angle of engagement of 30° in theconventional abrasive grain 10 shown in FIG. 24. This results inincreased grinding action.

The base face 11 of the abrasive grain 10 shown in FIGS. 25A and 25B hasthree-fold symmetry. The base face is thus invariable under a rotationby 120° in the plane of the base face 11. The above-described increasein the cutting effect is therefore independent of this orientation.

FIG. 26 shows a top view of a base face 11 of a further inventiveabrasive grain 10′. The outline 12 thereof likewise contains six corners15 and three linear sections 14. In contrast to the working exampleaccording to FIGS. 25A and 25B, the outline 12 here, however, has threesections 13 having strictly concave curvature. In addition, the internalangle α at the corners 15 here is 90°. The consequence of this is anangle of engagement of 0°, which leads to another improvement in cuttingaction. In addition, there is only a comparatively slight change in thecross section of the abrasive grain 10′ when the abrasive grain 10′ isworn away toward the center of the abrasive grain 10′ in the directionof a linear section 14.

In the third working example of an inventive abrasive grain 10″ shown inFIG. 27, the internal angle α is actually less than 90°, which leads toa negative angle of engagement δ, since the above-describedperpendicular S here runs outside the abrasive grain.

Finally, FIG. 28 shows a fourth working example of an inventive abrasivegrain 10′″, the outline 12 of which contains only concave sections 13and corners, but no linear sections.

The inventive abrasive grains can be produced, for example, by a processdescribed hereinafter: first of all, a dispersion of 200 g of α-Al₂O₃,0.4 g of MgO, 90 g of water as dispersion medium and 0.5 g of dispersantis produced. The MgO functions here as a nucleating agent. Thedispersant used may, for example, be the Dolapix CE64 product obtainablefrom Zschimmer & Schwarz, 56108 Lahnstein, Germany. The dispersion thusobtained is ground in a planetary ball mill at 200 revolutions perminute for 30 minutes, for example a PM400 planetary ball millobtainable from Retsch GmbH, 42781 Haan, Germany. Subsequently, theground dispersion is introduced into a silicone die as is described inmore detail below, containing depressions in the shape of the desiredabrasive grains. Thereafter, the volatile component, i.e. the water, isremoved from the dispersion. This gives rise to an abrasive grainprecursor which is removed from the die. In a final step, the precursoris sintered as bulk material at 1550° C. for 5 minutes. The dispersantis burnt out in the course of sintering.

FIGS. 29A and 29B show two views of a fifth embodiment. This abrasivegrain 10″″ differs from the idealized cylinder shape since the two basefaces 11 have slight concave curvature. The abrasive grain 10′″″ shownin FIGS. 30A and 30B contains two base faces 11 having slight convexcurvature. Deviations of this kind can arise, for example, by virtue ofthe production tolerances described in detail above.

FIG. 31 shows, in schematic form, a part of a die 30 with which anabrasive grain 10′″ according to FIG. 28 can be produced. The die 30 mayconsist, for example, of silicone. It contains a top side 32 and amultitude of identical depressions 31, only one single example of whichis shown here for simplification of the illustration. The depression 31has an open top face 35 through which a dispersion as described abovecan be introduced. The surface of the depression 31 contains a base face34 which is identical to the shape of the base face 11 of the abrasivegrain 10′″ and runs parallel to the top side 32 of the die 30. A lateralwall 36 which consists of a plurality of sections and is complementaryto the shell face of the abrasive grain 10′″ extends from the base face34.

An inventive abrasive article can be produced, for example, as follows:on an underlayer made from vulcanized fiber having a thickness of 0.8mm, a phenol resin dispersion as make coat precursor is applied in anamount of 120 g/m². Subsequently, 600 g/m² of the inventive abrasivegrains are applied by means of electrostatic scattering. Thereafter, themake coat precursor is cured to give a make coat. On top of the makecoat and the abrasive grains, a phenol resin dispersion is applied in anamount of 800 g/m² as size coat precursor, which is likewise cured.

Concept 1. An abrasive grain (10) having not more than three faces (11,12, 13), characterized in that the abrasive grain (10) contains at leastone edge (5, 6, 7, 8, 9) having a corner (1, 2, 3, 4) at at least oneend.

Concept 2. The abrasive grain (10) as described in any of the precedingconcepts, characterized in that the abrasive grain (10) has at leastfour corners (1, 2, 3, 4), especially exactly four corners (1, 2, 3, 4).

Concept 3. The abrasive grain (10) as described in concept 2,characterized in that the abrasive grain (10) has at least two edges ( )that are not in contact with one another, the two edges ( ) each beingbounded by two corners ( ) and a first straight connecting line formedbetween the corners ( ) that bound a first edge ( ) being arranged at anangle of 90°±50°, preferably 90°±30°, more preferably 90°±10°, withrespect to a second straight connecting line formed between the corners( ) that bound a second edge ( ).

Concept 4. The abrasive grain (10) as described in concept 2 or 3,characterized in that two planes that are formed between three corners(1, 2, 3, 4) each of the abrasive grain (10) form an angle between 70°and 140°, preferably between 80° and 130°, more preferably between 90°and 120°.

Concept 5. The abrasive grain (10) as described in any of concepts 2 to4, characterized in that the abrasive grain (10) has at least onefeature of symmetry, especially at least one plane of symmetry and/or atleast one axis of symmetry.

Concept 6. The abrasive grain (10) as described in any of the precedingconcepts, characterized in that the abrasive grain (10) has exactly twofaces (11, 12), the two faces (11, 12) of the abrasive grain beingcurved faces.

Concept 7. The abrasive grain (10) as described in any of concepts 1 to5, characterized in that the abrasive grain (10) has exactly three faces(11, 12, 13), at least two and especially all three faces (11, 12, 13)of the abrasive grain (10) being curved faces.

Concept 8. The abrasive grain (10) as described in any of the precedingconcepts, characterized in that it comprises or consists of a ceramicmaterial, especially a polycrystalline ceramic material, preferablyalumina, more preferably α-Al₂O₃.

Concept 9. A collective of abrasive grains (10), characterized in thatit comprises at least 20% by weight, preferably at least 50% by weight,more preferably at least 90% by weight, of abrasive grains (10) asdescribed in any of the preceding concepts.

Concept 10. A process for producing at least one abrasive grain (10) ora collective of abrasive grains (10) as described in any of thepreceding concepts, characterized by the following steps: (a) producingor providing a dispersion comprising α-alumina particles and/orparticles that can be converted to α-alumina, and at least one volatiledispersion medium, preferably water; (b) introducing the dispersion intoat least one depression of a die; (c) optionally squeegeeing an upperface of the die in order to remove at least a portion of the dispersionwhich stands above the upper face of the die; (d) removing a portion ofthe volatile components of the dispersion, so as to form at least oneabrasive grain precursor; (e) removing the abrasive grain precursor fromthe die; (f) optionally calcining the abrasive grain precursor; and (g)sintering the abrasive grain precursor in order to obtain at least oneabrasive grain (10).

Concept 11. A casting mold for producing at least one abrasive grain(10) as described in any of concepts 1 to 8, wherein the casting moldcomprises at least one die having at least one depression, preferably amultitude of depressions, having a particular surface, the surface beingcomplementary to the shape of at least part of the surface of theabrasive grain (10).

Concept 12. An abrasive article comprising a collective of abrasivegrains (10) as described in concept 9.

Concept 13. A process for producing an abrasive article as described inconcept 12, comprising a step in which a collective of abrasive grains(10) as described in concept 9 is fixed on and/or in a substrate (20),especially by means of a binder.

Concept 14. A process for grinding a surface, especially a paintedsurface, with an abrasive article as described in concept 12.

Concept 15. An abrasive grain (110; 210; 510; 510′; 810) comprising orconsisting of at least one component (120, 125; 220, 225; 510; 510′;810) having at least essentially the shape of a twisted geometricelementary body.

Concept 16. The abrasive grain (110; 210; 510; 510′; 810) as describedin concept 15, characterized in that at least one geometric elementarybody is a polyhedron, especially a prism, an antiprism, a pyramid or afrustopyramid.

Concept 17. The abrasive grain (210) as described in either of concepts15 and 16, characterized in that at least one geometric elementary bodyis a cone, especially a pyramid.

Concept 18. The abrasive grain (210) as described in either of concepts15 and 16, characterized in that at least one geometric elementary bodyis a frustocone, especially a frustopyramid.

Concept 19. The abrasive grain (110; 310; 510; 510′; 810) as describedin either of concepts 15 and 16, characterized in that at least onegeometric elementary body is a cylinder, especially a prism.

Concept 20. The abrasive grain (110; 210) as described in any of thepreceding concepts, characterized in that the abrasive grain (110; 210)has a base element (120; 220) having a bottom side (121; 221) and anopposite top side (122, 222), and also at least one top element (125;225) having a bottom side (126; 226) disposed upon the top side (122;222) of the base element (120; 220), the base element (120; 220) and/orat least one top element (125; 225) constituting one of the components(120, 125; 220, 225).

Concept 21. The abrasive grain (110; 210; 510; 510′; 810) as describedin any of the preceding concepts, characterized in that it comprises orconsists of a ceramic material, especially a polycrystalline ceramicmaterial, preferably alumina, more preferably α-Al₂O₃.

Concept 22. A collective of abrasive grains (110; 210; 510; 510′; 810),characterized in that it comprises at least 20% by weight, preferably atleast 50% by weight, more preferably at least 90% by weight, of abrasivegrains (110; 210) as described in any of the preceding concepts.

Concept 23. A process for producing at least one abrasive grain (110;210; 510; 510′; 810) or a collective of abrasive grains (110; 210; 510;510′; 810) as described in any of the preceding concepts, characterizedby the following steps: (a) producing or providing a dispersioncomprising α-alumina particles and/or particles that can be converted toα-alumina, and at least one volatile dispersion medium, preferablywater; (b) introducing the dispersion into at least one depression (31)of a die; (c) optionally squeegeeing an upper face of the die in orderto remove at least a portion of the dispersion which stands above theupper face of the die; (d) removing a portion of the volatile componentsof the dispersion, so as to form at least one abrasive grain precursor;(e) removing the abrasive grain precursor from the die; (f) optionallycalcining the abrasive grain precursor; and (g) sintering the abrasivegrain precursor in order to obtain at least one abrasive grain (110;210; 510; 510′; 810).

Concept 24. A process for producing at least one abrasive grain (510;510′; 810) or a collective of abrasive grains (510; 510′; 810),especially at least one abrasive grain (510; 510′; 810) or a collectiveof abrasive grains (510; 510′; 810) as described in any of concepts 15to 21, characterized by the following steps: (a) producing or providinga dispersion comprising α-alumina particles and/or particles that can beconverted to α-alumina, and at least one volatile dispersion medium,preferably water, and optionally at least one organic additive; (b)extruding the dispersion through an exit orifice (507; 507′; 507″;507′″; 507″″) of a nozzle (506; 506′; 506″; 506′″; 506″″), the exitorifice having at least essentially the shape of a twisted cylinder,such that an extrudate is obtained; (c) severing the extrudate to obtainabrasive grain precursors; (d) optionally calcining the abrasive grainprecursors; and (e) sintering the abrasive grain precursors in order toobtain at least one abrasive grain (510; 510′; 810).

Concept 25. A process for producing at least one abrasive grain or acollective of abrasive grains, especially at least one abrasive grain ora collective of abrasive grains as described in any of concepts 15 to21, characterized by the following steps: (a) producing or providing adispersion comprising α-alumina particles and/or particles that can beconverted to α-alumina, and at least one volatile dispersion medium,preferably water, and optionally at least one organic additive; (b)producing a film from the dispersion; (c) severing the film produced instep b) to form film sections; (d) shaping the film sections produced instep c) to obtain abrasive grain precursors; (e) optionally calciningthe abrasive grain precursors; and (f) sintering the abrasive grainprecursors in order to obtain at least one abrasive grain.

Concept 26. A casting mold for producing at least one abrasive grain(110; 210; 510; 510′; 810) as described in any of concepts 15 to 20,wherein the casting mold comprises at least one die having at least onedepression, preferably a multitude of depressions, having a particularsurface, the surface being complementary to the shape of at least partof the surface of the abrasive grain (110; 210; 510; 510′; 810).

Concept 27. An abrasive article comprising a collective of abrasivegrains (110; 210; 510; 510′; 810) as described in concept 22.

Concept 28. A process for producing an abrasive article as described inconcept 12, comprising a step in which a collective of abrasive grains(110; 210; 510; 510′; 810) as described in concept 22 is fixed on and/orin a substrate, especially by means of a binder.

Concept 29. A process for grinding a surface, especially a paintedsurface, with an abrasive article as described in concept 12.

Concept 30. An abrasive grain (100; 400; 500; 600; 700; 800; 900; 1000)having at least six faces (110; 410; 510; 610; 710; 810; 910; 1010),characterized in that at least one of the faces (110; 410; 510; 610;710; 810; 910; 1010) has concave curvature (111; 711).

Concept 31. The abrasive grain (100; 400; 500; 600; 700; 800; 900) asdescribed in concept 30, characterized in that at least one dished face(110) is curved in at least two directions (114, 115).

Concept 32. An abrasive grain (200, 300), especially as described inconcept 30 or 31, characterized in that the abrasive grain (200; 300)has a structure with at least one reentrant corner (216; 316).

Concept 33. The abrasive grain (100; 300; 400; 500; 600; 700; 800; 900)as described in concept 30, 31 or 32, characterized in that the abrasivegrain (100; 300; 400; 500; 600; 700; 800; 900) has at least one curvededge (113; 313; 713; 813), especially a concave curved edge (113; 713;813).

Concept 34. The abrasive grain as described in any of the precedingconcepts, characterized in that the abrasive grain (100; 200; 300; 400;500; 600; 700; 800; 900) has a structure with corners (112; 312; 412;512; 612; 712; 812; 912) and at least some of the corners, especiallyall the convex corners (112; 312; 412; 512; 612; 712; 812; 912),correspond to the corners of an imaginary polyhedron, especially aPlatonic solid, an Archimedean solid, a Catalan solid, a prism, anantiprism, or a Platonic solid, Archimedean solid, Catalan solid, prismor antiprism with linear distortion.

Concept 35. The abrasive grain (100; 200; 300; 400; 500; 600; 700; 800;900; 1000) as described in any of the preceding concepts, characterizedin that it comprises or consists of a ceramic material, especially apolycrystalline ceramic material, preferably alumina, more preferablyα-Al₂O₃.

Concept 36. A collective of abrasive grains (100; 200; 300; 400; 500;600; 700; 800; 900; 1000), characterized in that it comprises at least20% by weight, preferably at least 50% by weight, more preferably atleast 90% by weight, of abrasive grains (100; 200; 300; 400; 500; 600;700; 800; 900; 1000) as described in any of the preceding concepts.

Concept 37. A process for producing at least one abrasive grain (100;200; 300; 400; 500; 600; 700; 800; 900; 1000) or a collective ofabrasive grains (100; 200; 300; 400; 500; 600; 700; 800; 900; 1000) asdescribed in any of the preceding concepts, characterized by thefollowing steps: (a.) producing or providing a dispersion comprisingα-alumina particles and/or particles that can be converted to α-alumina,and at least one volatile dispersion medium, preferably water; (b.)introducing the dispersion into at least one depression of a die; (c.)optionally squeegeeing an upper face of the die in order to remove atleast a portion of the dispersion which stands above the upper face ofthe die; (d.) removing a portion of the volatile components of thedispersion, so as to form at least one abrasive grain precursor; (e.)removing the abrasive grain precursor from the die; (f.) optionallycalcining the abrasive grain precursor; and (g.) sintering the abrasivegrain precursor in order to obtain at least one abrasive grain (100;200; 300; 400; 500; 600; 700; 800; 900; 1000).

Concept 38. A casting mold for producing at least one abrasive grain(100; 200; 300; 400; 500; 600; 700; 800; 900; 1000) as described in anyof concepts 30 to 35, wherein the casting mold comprises at least onedie having at least one depression, preferably a multitude ofdepressions, having a particular surface, the surface beingcomplementary to the shape of at least part of the surface of theabrasive grain (100; 200; 300; 400; 500; 600; 700; 800; 900; 1000).

Concept 39. The casting mold as described in concept 38, characterizedin that the casting mold has at least one further shaping element,especially a further die or a ram element, with which, in addition tothe face shaped in the die, at least some of the rest of the surface ofthe abrasive grain (100; 200; 300; 400; 500; 600; 700; 800; 900; 1000)can be shaped.

Concept 40. An abrasive article comprising a collective of abrasivegrains (100; 200; 300; 400; 500; 600; 700; 800; 900; 1000) as describedin concept 36.

Concept 41. A process for producing an abrasive article as described inconcept 40, comprising a step in which a collective of abrasive grains(100; 200; 300; 400; 500; 600; 700; 800; 900; 1000) as described inconcept 36 is fixed on and/or in a substrate, especially by means of abinder.

Concept 42. A process for grinding a surface, especially a paintedsurface, with an abrasive article as described in concept 40.

Concept 43. An abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) in theshape especially of a straight cylinder having two opposite base faces(11), characterized in that the base faces (11) have an outline (12)including at least one concave section (13).

Concept 44. The abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) asdescribed in concept 43, characterized in that the outline (12) has atleast one corner (15).

Concept 45. The abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) asdescribed in concept 44, characterized in that the outline (12) at theedge (15) defines an inner angle (α) of the base face (11) within therange from 65° to 120°, preferably from 65° to 115°, further preferablyfrom 75° to 105°, more preferably from 85° to 95° and most preferably90°.

Concept 46. The abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) asdescribed in any of the preceding concepts, characterized in that theoutline (12) has at least one linear section (14).

Concept 47. The abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) asdescribed in concept 46, characterized in that at least one linearsection (14) runs at an angle with respect to a support plane (E) of theabrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″) of at most 20°,preferably at most 10°, more preferably at most 5°.

Concept 48. The abrasive grain (10; 10′; 10 ″; 10′″; 10″″; 10′″″) asdescribed in any of the preceding concepts, characterized in that atangent (T) to at least one point on the outline (12) runs at an angleto a perpendicular (S) that runs at right angles to the support plane(E) of the abrasive grain (10; 10′; 10″; 10′″; 10″″; 10′″″), this anglebeing in the range from −30° to +30°, preferably from −25° to +25°,further preferably from −15° to +15°, more preferably from −5° to +5°and most preferably 0°.

Concept 49. The abrasive grain (10; 10′; 10 ″; 10′″; 10 ″″; 10′″″) asdescribed in any of the preceding concepts, characterized in that theoutline (12) has at least three, preferably exactly three, concavesections (13) whose respective ends are corners (15) of the outline(12), and in that the outline (12) has a linear section (14) between anytwo concave sections (13).

Concept 50. The abrasive grain (10; 10′; 10 ″; 10′″; 10″″; 10′″″) asdescribed in any of the preceding concepts, characterized in that theratio of the height (h) of the abrasive grain (10; 10′; 10″; 10′″; 10″″;10′″″) and the diameter of a circle enveloping the base faces (11) isnot more than 1, preferably not more than 0.8, more preferably not morethan 0.6.

Concept 51. The abrasive grain (10; 10′; 10 ″; 10′″; 10″″; 10′″″) asdescribed in any of the preceding concepts, characterized in that itcomprises or consists of a ceramic material, especially apolycrystalline ceramic material, preferably alumina, more preferablyα-Al₂O₃.

Concept 52. A collective of abrasive grains (10; 10′; 10″; 10′″; 10″″;10′″″), characterized in that it comprises at least 20% by weight,preferably at least 50% by weight, more preferably at least 90% byweight, of abrasive grains (10; 10′; 10″; 10′″; 10″″; 10′″″) asdescribed in any of the preceding concepts.

Concept 53. A process for producing at least one abrasive grain (10;10′; 10″; 10′″; 10″″; 10′″″) or a collective of abrasive grains (10;10′; 10″; 10′″; 10″″; 10′″″) as described in any of the precedingconcepts, characterized by the following steps: (a.) producing orproviding a dispersion comprising α-alumina particles and/or particlesthat can be converted to α-alumina, and at least one volatile dispersionmedium, preferably water; (b.) introducing the dispersion into at leastone depression (31) of a die (30); (c.) optionally squeegeeing an upperface (32) of the die (30) in order to remove at least a portion of thedispersion which stands above the upper face (32) of the die (30); (d.)removing a portion of the volatile components of the dispersion, so asto form at least one abrasive grain precursor; (e.) removing theabrasive grain precursor from the die (30); (f.) optionally calciningthe abrasive grain precursor; and (g.) sintering the abrasive grainprecursor in order to obtain at least one abrasive grain (10; 10′; 10″;10′″; 10″″; 10′″″).

Concept 54. A casting mold (30) for producing at least one abrasivegrain (10; 10′; 10″; 10′″; 10″″; 10′″″) as described in any of concepts43 to 51, wherein the casting mold (30) comprises at least onedepression (31), preferably a multitude of depressions (31), having aparticular surface, the surface being complementary to the shape of atleast part of the surface of the abrasive grain (10; 10′; 10″; 10′″;10″″; 10′″″).

Concept 55. An abrasive article (40) comprising a collective of abrasivegrains (10; 10′; 10″; 10′″; 10″″; 10′″″) as described in concept 52.

Concept 56. A process for producing an abrasive article (40) asdescribed in concept 55, comprising a step in which a collective ofabrasive grains (10; 10′; 10″; 10′″; 10″″; 10′″″) as described inconcept 52 is fixed on and/or in a substrate, especially by means of abinder (42).

Concept 57. A process for grinding a surface, especially a paintedsurface, with an abrasive article (40) as described in concept 55.

1. An abrasive grain comprising: two opposite base faces each definingan outline including at least one concave section, wherein the abrasivegrain is in the shape of a straight cylinder.
 2. The abrasive grain asclaimed in claim 1, wherein the outline has at least one corner.
 3. Theabrasive grain as claimed in claim 2, wherein an edge of the outlinedefines an inner angle of one of the two opposite base faces within arange from 65° to
 120. 4. The abrasive grain as claimed in claim 3,wherein the inner angle is within a range from 65° to 115°.
 5. Theabrasive grain as claimed in claim 3, wherein the inner angle is withina range from 75° to 105°.
 6. The abrasive grain as claimed in claim 3,wherein the inner angle is within a range from 85° to 95°.
 7. Theabrasive grain as claimed in claim 3, wherein the inner angle is 90°. 8.The abrasive grain as claimed in claim 1, wherein the outline defines atleast one linear section.
 9. The abrasive grain as claimed in claim 8,wherein the at least one linear section runs at an angle with respect toa support plane of the abrasive grain of at most 20°.
 10. The abrasivegrain as claimed in claim 8, wherein the at least one linear sectionruns at an angle with respect to a support plane of the abrasive grainof at most 10°.
 11. The abrasive grain as claimed in claim 8, whereinthe at least one linear section runs at an angle with respect to asupport plane of the abrasive grain of at most 5°.
 12. The abrasivegrain as claimed in claim 1, wherein: a tangent to at least one point onthe outline runs at an angle to a perpendicular line that runs at rightangles to a support plane of the abrasive grain, and the angle is in arange from −30° to +30.
 13. The abrasive grain as claimed in claim 12,wherein the angle is in a range from 25° to +25°.
 14. The abrasive grainas claimed in claim 12, wherein the angle is in a range from −15° to+15°.
 15. The abrasive grain as claimed in claim 12, wherein the angleis in a range from −5° to +5°.
 16. The abrasive grain as claimed inclaim 12, wherein the angle is 0°.
 17. The abrasive grain as claimed inclaim 1, wherein: the outline defines at least three concave sectionswhose respective ends are corners of the outline, and the outlinedefines a linear section between any two concave sections of the atleast three concave sections.